Equipment TP MAW ANA Gland Steam Condenser

List of KKS
KKS Component Type Manufacturer Supplier

MAM60AC010 Gland Steam Condenser 1203.100601 AEL ANA
MAM65AN110 Fans 1CV3083A KARL KLEIN ANA
MAM65AN120 Fans 1CV3083A KARL KLEIN ANA
MAM65AA005 Butterfly Valve GD‐6 JASTA ANA
MAM65AA510 Check Valve ZRK3 RITAG ANA
MAM65AA520 Check Valve ZRK3 RITAG ANA
MAM60AA010 Globe Valve 1D00222 AVA ALMS ANA
MAM60AA030 Globe Valve 1D00222 AVA ALMS ANA
MAM60AA020 float steam trap UNA 45 GESTRA ANA
LCA10AA310 Safety Valve Type 437 LESER ANA
MAM60CP510 Pressure Gauge 233.50.100 WIKA ANA
Betriebsdokumentation
Operating Documentation
Kommissions-Nr.: Auftraggeber: Siemens Energy Global
Commission-N°:
F220-3511 Customer: GmbH & Co. KG
Stück/Benennung: 1 Stk. Leckdampfkondensatormodul Bestell-Nr.:
Quantity/description: Order-N°:
7001021687
1 pc. Gland Steam Condenser Modul
Fabrik-Nr.: Projekt:
Factory-N°:
4020004 Project:
TIMOR 1
Zeichnungs-Nr.: Projekt-Nr.:
Drawing-N°:
67-3265 Project-N°.:
BB2285A
Baujahr: Pos.-Nr.:
Year of manufacture:
2021 Pos.-N°.:
--
ANA
ANA Prozesstechnik GmbH
Herrfurthstraße 9 • D - 06217 Merseburg

Tel.: (03461) 457-0
Fax: (03461) 457-200
eMail: [email protected]
www.ana-gmbh.com
ANA Prozesstechnik GmbH • Herrfurthstraße 9 • D - 06217 Merseburg • Tel.: +49 3461-4570 • FAX: +49 3461-457200
Inhaltsverzeichnis
List of contents

Commission-N°:
7001021687
Factory-N°:
4020004 Project:
TIMOR 1
Drawing-N°:
BB2285A
Baujahr: Pos.-Nr.:
2021 Pos.-N°.:
--
Zeichnung 67-3265
1.
Drawing 67-3265
Betriebsanleitung
2.
Operation Manual
Fließbild
3.
Flow sheet
Montageanleitung und Sicherheitshinweise
4.
Installation- and safety instruction
Lagerungshinweise
5.
Storage instructions
Leckdampfkondensator
6.
Gland Steam Condenser
Radial-Ventilator
7.
Radial Fan
Armaturen
8.
Valves
Sicherheitsventile
9.
Safety Valves
Messtechnik
10.
Measurement
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24
2 TECHNISCHE DATEN / TECHNICAL DATA
Vorschriften:
Code requirements: ASME VIII Div.1 Ed. 2019
Abnahme:
4 2 Firmenschild / name plate Inspection by
4 SECTION A-A DESIGNER: ANA Prozesstechnik GmbH

4 SECTION B-B Rohrraum
A MADE IN GERMANY
MANUFACTURER: AEL Apparatebau GmbH Mantelraum
shell side tube side
3 657
Hersteller/ Manufacturer max. zul. Druck
max. allowable pressure PS
min. / max. FV / 0,5 0 / 27,05 bar Ü
bar g
A
ANA PROZESSTECHNIK GmbH
11 MAM65AA005 Herrfurthstraße 9
06217 Merseburg
max. zul. Temperatur
Allowable working temperature TS
min. / max. 5 / 325 5 / 60 °C
328.5 328.5 AEL APPARATEBAU GmbH
Verfahrensdruck bar Ü
ANA-Kommission
ANA-Commission F220-3511 Operating pressure -0,01...0,0 15,19...15,28 bar g
210 803 Verfahrenstemperatur 67,2...237,2
2 11 MAM65/02 Operating temperature
40,8...41,8 °C
Prüfüberdruck mit Wasser 20°C - Lage horizontal 3,0 36,5
Benennung bar Ü
Designation
GLAND STEAM CONDENSER MODULE testing pressure with water 20°C - horicontal position PT
bar g
mit Luft (Leckagetest)
B N/A N/A
N3 with air (leakage test)
2 11 MAM65AA520 11 MAM65AA510 2 AEL-Fabrik-Nr. Baujahr

Inhalt gesamt 70,0 12,0 l B
AEL-Serial No. 4020004 2021 volume total
Year built
Wärmeaustauschfläche 2
Heat exchanging area 1,37 m
600
Zeichnung-Nr. Leergewicht Fabrik-Nr.
Drawing No. 67-3265 Empty weight 610 kg Factory-No. 4020004
425
Baujahr
2021
2 11 MAM65AN120 Year of construction
Medium Luft, Dampf Kühlkondensat
air, steam cooling condensate
11 MAM60CP510 11 MAM65AN110 2
medium
gasförmig flüssig
Bei Ersatzteilbestellung Fabrik-Nr.und Baujahr angeben.
When ordering spares, please state serial no. and year built.
Aggregatzustand
state of matter gaseous liquid
C Dichte 0,53...980 3
992...993 kg/m
11 LCA10AA310
density
C
11 LCA10/03
toxisch / brennbar / explosiv nein / no nein / no
1588
toxic / flammable / explosive
2
1370 [1375]
Fluidgruppe -- --
416 N4 Fluid group
4 75 75 Schweissnahtfaktor
Weld efficiency factor 0,85 0,85
2 Firmenschild Kondensator / name plate condenser Korrosionszuschlag

Corrosion allowance 1,6 1,6 (except stainless steel) mm
Längsnähte
N6 11 LCA10/01
945
945
Röntgen / U.S.-Pruefung
11 LCA10/02 Long. welds
145 56
D 2 der Schweissnähte Rundnähte
N6 FS
MADE IN GERMANY Circ. welds
Hersteller/ Manufacturer X-ray / ultrasonic testing
of welds T-Stoesse D
ANA PROZESSTECHNIK GmbH T-joint
N2 N1 Herrfurthstraße 9
549
06217 Merseburg Andere Prüfungen siehe Schweiß- und

ANA-Kommission AEL APPARATEBAU GmbH Other tests
ANA-Commission F220-3511-002 Prüfplan
350
11 LCA10AA/04 Benennung in acc. to test plan
300
300
Designation gland steam condenser - 11 MAM60AC010 Schweissverfahren
N7 geltende Normen
Welding process
PF. EL. 5000 N7 N7 Die Rohrleitung ist während des Transports demontiert. PF. EL. 5000 applicable norm
AEL-Fabrik-Nr.
AEL-Serial No.
301 542 ; 3120002
ASME VIII Div.1 Ed. 2019
Baujahr
Year built 2021
Schweisszusatzwerkstoff
Welding filler material
Vorwärmung ja/nein
E The Piping is seperate during transport. 2 Mantelseite / shell side Rohrseite / tube side Pre-Heating yes/no
min./max. zulässiger Druck
95 min./max. allowed pressure
[PS] FV / 0,5 bar g 0 / 27,05 bar g Wärmebehandlung ja/nein
11 LCA10AA/05
min./max. zulässige Temperatur

min./max. allowed temperature
[TS] 5 / 325 °C 5 / 60 °C
Heat treatment
Isolierung warm/kalt
yes/no
E
2 170 170 Prüfdruck [PT] on site mm
403
Test pressure 3,0 bar g 36,5 bar g Insulation warm/cold

11 MAM60AA010 Inhalt [V]
15,0 l 7,6 l Auskleidung
Volume -- mm
459 Leergewicht Betriebsgewicht
Lining
11 MAM60AA020 Empty weight Operating weight Oberflächenausführung aussen gemäß ANA Anstrichkonzept
N5 100 kg 115 kg
Surface finish outside
11 MAM60AA030 2 Prüfdatum Monat/Jahr
Test date Month/Year acc. to ANA painting concept
11 MAM60/08 Bei Ersatzteilbestellung Fabrik-Nr.und Baujahr angeben.
2 When ordering spares, please state serial no. and year built.
F
hinter der Flanschverbindung gehaltert
Gewicht
Anschlussrohrleitung muss unmittelbar
610 kg
11 MAM60/01

directly behind the flange connection!
Weight
N8 Gewicht mit Wasserfüllung F
Connecting pipe must be supported
hinter der Flanschverbindung gehaltert werden! Weight full with water 692 kg
1447
Connecting pipe must be supported Bemerkungen Allgemeintoleranzen: für Schweißkonstruktionen - EN ISO 13920 Klasse-B+F ; Lastspiele ≤ 500 ( gem. ASME Sec.VIII );
1507
Remarks
Sicherheitsventil (Rohrraum) Einstelldruck 27,05 barg
11 MAM60/03
11 MAM65/01 general allowances: for welding construction - EN ISO 13920 class-B+F; load application ≤ 500 ( acc. to ASME Sec.VIII ),
Safety valve (tube side) setting pressure 27,05 barg
1000
Die Armatureneinheit ist während des Transports demontiert.

11 MAM65/03
The valve unit is seperate during transport. 2 STUTZENTABELLE / TABLE OF NOZZLES

4
750
G Bez. TAG Anz. Benennung DN Standard Dichtfläche Rohrabmessung Bemerkung Material
designation class
des. No. no. NPS standard gasket surf. dimens. of tubes remarks material G
Kondensateintritt ASME
2 N1 11 LCA10 01 1 3" 300 RF Ø88,9 Typ WN SA-105
cooling condensate inlet B16.5
werden!
Die Rohrleitung ist während des Transports demontiert. Kondensataustritt ASME

2 The Piping is seperate during transport. N2 11 LCA10 02 1 3" 300 RF Ø88,9 Typ WN SA-105
cooling condensate outlet B16.5
4 ISOMETRIC VIEW Abluft vom Gebläse ASME
N3 11 MAM65 02 1 3" 150 RF Ø88,9 Typ WN SA-105
5 exhaust ait from fans B16.5
H N9 Dampfeintritt ASME
N9
9 9 4 N4 1
steam inlet
3" 150
B16.5
RF Ø88,9 Typ WN SA-105
H
230 Abfluss des
Abdampfkondensators ASME Typ WN
4 416 [418] 4 573 [580] N5 11 MAM60 01 1 3" 150 RF Ø88,9 SA-105
waste steam condenser B16.5
hotwell drain
11 N6
11 LCA10 06
2
Entlüftung Kondensator
1/2" -- -- G1/2" -- Innengewinde
SA-105
9 &11 LCA10 07 ventilation condenser female
J 11 LCA10 04 Entleerung Kondensator Innengewinde
N7 2 1/2" -- -- G1/2" Ø33,4 SA-105
&11 LCA10 05 emptying condenser female J
Austritt Kondensat ASME Typ WN
14 N8 11 MAM60 08 1 1" 150 RF Ø33,4 SA-105
outlet condensate B16.5
Entleerung
Kondensatschleife -- -- -- Innengewinde
N9 1 1/2" G1/2" SA-105
female
2 emptying condensate loop
11 N10 11 LCA10 03 1
Austritt Sicherheitsventil
1/2" -- -- G1/2" -- Innengewinde
316L
outlet safety valve female
K
17 FS 1
Anlagenschild
-- -- -- -- 105 x 105 -- --
K
name plate of the unit
2
18 Transportangaben / Transport information
N TOP VIEW 17
W O 2 Zulässige Stutzenbelastung F = 5000N
4 N 10 8 Permissible forces and moments
S 1445 L
B W O 345 FR MR
ML
FR MR
ML
667 778 S FU FU
150 150
L 12
MAM65AA020
1 FL
MU
FL
MU
3
R
Da
15
93.5
13 cylinder sphere
GROBSTÜCKLISTE / LIST OF PARTS 16 FR FL FU MR ML MU M
Pos. No. Benennung / designation Nennweite Material Stutzen
/ size 310 n18 n18
12 nozzle kN kN kN kNm kNm kNm
18 1 Anlagenschild name plate -- SS
485
M 147 [153] N1;N2 1,35 1,15 1 0,3 0,6 0,465

Tragöse lifting lug NG1 - t=10mm t=10mm N3;N4 1,35 1,15 1 0,3 0,6 0,465
17 4 1.0038 121
DIN 28086 4 7
Erdungslasche earthing
16 1 -- SS
lug
1357
970
15 1 Traggestell support -- 1.0038

Druckmessung pressure N10 373
6 N
14 1 1/2'' --
measuring
Kondensomat steam trap --
N 13 1 1''
C.L Condenser
Absperrschieber Gate --
12 2 1''
780
valve
Rückschlagklappe --
11 2 3''
Non-return valve Detail Erdungslasche / Detail Verbindung Traggestell /
93.5
Sicherheitsventil 3
MAM65AA010 detail earthing connection
10 1 rohrseitig safety valve 1/2'' -- Detail connection support frame P
tube side (1:2) (1:2) Maße in [...] sind Ist-Maße
390
150 90 4 measures in [...] are actual size

Ohne schriftliche Genehmigung ist die Vervielfaeltigung, Bekanntmachung oder Weitergabe an Dritte
P Absperrklappe mit 90 150

--
Das Urheberrecht an diesen technischen Dokumenten verbleibt der ANA Prozesstechnik GmbH.
9 3 Rasthebel butterfly 3''

valve manual 675
t=10mm t=10mm
30 20
AEL-Auftrags.Nr.: 4020004
Entlüftungsleitung 1696
10
nicht gestattet. Zuwiderhandlung zieht zivil- und strafrechtliche Folgen nach sich.
C 2020 by ANA Prozesstechnik GmbH

8 1 Kondensatableiter drain 1/2'' SS B n18 n18 4 07.05.2021 SMI ARI ARI as built
3 19.02.2021 SMI ARI ARI überarbeitet / revised
60
line blower
70
n11
45
Entleerungsleitung
2 10.11.2020 SMI ARI ARI überarbeitet / revised Q
1 ZQA
7 2 1/2'' SS 13.10.2020 SMI ARI überarbeitet / revised
Gebläse drain line blower 4
150
0 27.08.2020 SMI ZQA ARI Erstausgabe / first issue
Q 6 Kondensatablaufleitung 70 Zust. Datum erstellt geprüft genehmigt Bemerkungen

1 3'' CS Date drawn checked approved Remarks
A A
Rev.
condensate line M16 Benennung / Description:
Abluftleitung exhaust http://www.ana-gmbh.com
5 1
line
3'' CS 150 150 e-mail: [email protected]
GLAND STEAM CONDENSER
Zum Heben der Anlage wird die Verwendung einer einstellbaren H- Traverse empfohlen. MODULE - LAYOUT
Bypassleitung bypass 345 Herrfurthstrasse 9 * D-06217 Merseburg
4 1 3'' CS Die Anlage darf nur an den 4 Hebeösen am Gestell gehoben werden. Tel.: 03461/457-0 * Fax: 03461/457-200 TIMOR 1 - 11 MAM60AC010
line
Saugleitung suction line Es dürfen nur handelsübliche und für das Gewicht der Anlage zulässige Anschlagemittel bestimmungsgemäß verwendet werden. Fertigungsauftrag-Nr.: Blattgröße: Maßstab: Zeichnung-Nr. / Drawing-No.: Rev. R
3 1 3'' CS Production order-No.: Sheet Size: Scale: Zust.
R Grauguss
2 2 Gebläse blower 3'' For lifting the unit, the use of an adjustable H- cross beam ist recommended.
F220-3511
(14 487/2020)
A0 1 : 10 67-3265 4
(GG20)
The unit may be lifted only at the lifting eyes at the rack. Werkstoff / Material: Hierzu / To this: Kunde / Customer: Siemens Gas & Power GmbH & Co. KG
Oberflächenkondensator
1 1 1,37 m2 CS/SS Only commercial and slinging means permisible for the weight of the unit may be intended used. condenser tube sheet& tubes: 316L condenser shell: CS 65-2432 Projekt / Project: TIMOR 1
surface condenser supp.rack: 1.0038 piping: CS Bestell-Nr. / Order-No.: 7001021687
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24
ANA Prozesstechnik GmbH Telefon (03461) 457-0
Telefax (03461) 457-200
Herrfurthstraße 9 [email protected]
D-06217 Merseburg www.ana-gmbh.com
Operation Manual
Customer Siemens Energy Global GmbH & Co. KG
Order number (offer number): F220-3511 (P220-4728)
Type: Gland Steam Condenser Modul
Key word BB2285 – TIMOR 1
1. Beschreibung/Description
Lüfter/ Fan 2x100% with Siemens Motor
Produkt:
Wrasendampf/Gland steam 1x100% surface condenser + 10%
Kondensator/condenser
Leistungsreserve
2. Leistungsdaten Kondensator /Performance data condenser

Druck/ Massenstrom/
Betriebsdaten/ Temp.
pressure mass flow
operating conditions
bar (a) °C kg/h
Lastfall/Load case Design-Case
Wrasendampf/ Luft/air 79,2
0,99 237,2
Gland steam Dampf/Steam 61,2
Kühlwasser/ ein/in 16,28 40,8
33000
cooling water aus/out 16,28-0,087 41,8
Gasaustritt/ Luft/air 79,2
0,988 67,2
gas outlet Dampf/steam 19,1
Dampfkondensat /
Wasser/ water 0,988 67,2 42,1
Steam condensate
Thermische Auslegung/
Suction flow acc. customer specification 5-62430-BB2285A
thermal calculations
3. Design and principle of operation
Related P&ID Gland steam system 0-06420-BB2284A-02
The steam flows into the shell side of the gland steam condenser where it is channeled around the internal
tubes by means of various baffle plates whereby it largely condenses on the cold cooling water pipes. The
condensate is collected in a water loop and leaves the module. Any non-condensable fractions of the
steam will be sucked in by the operating radial fan and will exit the module. The radial fan is specifically
designed to extract any non-condensed inert gases from the gland steam condenser module.
The cooling water flows through the condenser in single-pass. Cooling water enters the tube side of the
gland steam condenser, flows through the internal tubes, and exits the condenser. To guarantee the good
working order of functionality of the gland steam condenser, the flow directions shall not be reversed or
changed. Various ports are provided on the condenser for draining and venting.
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Operation Manual
4. (Un-) Installation Advices

All safety information or instructions mentioned herein will apply to the assembly, installation or
dismantling of plant sections or components even though the same may not be explicitly mentioned.
As with any activity, the installation job site will be off limits to unauthorized personnel.
As installation work may have to be carried out from a raised position and as detached or heavy
components may have to be handled, such work must be performed with particular care.
Assembly or installation work must not be carried out under pipes or fittings that have not been properly
fastened. Generally, make sure any work is carried out from a safe position.
Pipes or fittings may only be moved or handled by means of a hoist or lifting gear such as a crane or
manipulator. Moreover, they must be positively supported for safe working.
Here, too, it is mandatory to wear protective clothing, specifically hard hats and work gloves.
Exclusively suitable, safe and approved tools in good working order only may be used for such work.
A second backup person must be present for high-risk work or work at a raised position.
Plant components or sections may only be installed, dismantled or removed while de-energized.
When bolting up two pipes or their flanged ends, be sure to safely fasten and fix the flanges in position to
avoid hazards through falling parts.
Work on electrical or electronic systems may only be carried out by purposefully trained and adequately
qualified personnel.
Hazards through electric energy must be excluded. For detailed information or reference refer to the
regulations issued by VDE (the German Association for Electrical, Electronic & Information Technologies)
or local utilities.
Work on electrical or other drives may only be performed after the respective drive has been deactivated,
and secured against restart.
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Operation Manual
5. Disclaimer
ANA Prozesstechnik GmbH will not accept responsibility for any damage resulting from the non-
observance of these commissioning instructions or any documents included therein or of any assembly,
operating, maintenance or servicing instructions issued for individual components respectively.
Moreover, ANA Prozesstechnik GmbH disclaims liability for any damage caused by other uses of the gland
steam condenser module than the designated use, or by structural changes to the module.
This equally applies to any damage that could have been avoided through regular monitoring of
components subject to wear or through timely and proper maintenance or servicing.
In addition, ANA Prozesstechnik GmbH disclaims liability for any damage caused by acts of God or Force
Majeure, or extraneous cause.
During the warranty period, any required repairs or changes to the system should be exclusively done by
our servicing staff, or by your operating personnel or by external contractors following our prior written
consent only.
6. Operation Instructions
Make sure all persons working on or in connection with this gland steam condenser module will have
thoroughly read and understood these assembly instructions. All such work may exclusively be performed
by duly qualified and trained personnel only.
6.1. Before Start-up

Before starting the gland steam condenser module up, some precautions or provisions must be made, as
described in the technical comments. All the activities mentioned below must have been successfully
finalized before this unit may be started up.
 Set the module up.

 Fixing the module.
 Hook up all pipes / transfer points.
 Connect all ground connections (two (2) nos. on the base frame).
 Inspect / retighten all screw connections.
 Connect all electrical equipment items (level switch, radial fan).
 Work off the checklist - see technical comments.
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Operation Manual
The starting-up procedure may only commence once the checklist will have been worked off and the
quality plan will have been signed off.
• Inspect all transfer points for proper connection and hook-up.

• All shut-off valves must be open.
• The radial fans must be started up in line with the operating and maintenance instructions.
• Motors are activated in line with the operating and maintenance instructions.
• The condensate water supply must be opened.
• After that only, the steam may be allowed to flow into the module.
• Preferably, the steam should be opened gradually to allow the material to gradually adapt to the
temperature (difference).
6.2. Operation
Check operating values such as the steam temperature at the measuring points provided for this purpose
during the whole time of operation.
To guarantee the ongoing monitoring of the operating values and to avoid risks of accident, the facility
Operator or Owner respectively shall the gland steam condenser module and its proximity are maintained
in a state of order and cleanliness at all times while the unit is in operation. Moreover, the facility Operator
or Owner must guarantee that all instruments or measuring points are easily readable and in good working
order. The same will apply to the good working order of all valves or fittings.
If there is excessive noise on the gland steam condenser module, establish the cause, and eliminate as and
if required. Should it not be possible to establish the cause or should the noise level be alarmingly high,
shut this unit down as described here.
6.3. Shutdown
Before shutting the gland steam condenser module off and thus discontinuing the steam supply, it must
be guaranteed that this operation will be coordinated and concerted with the remaining automation
concept and the existing fail-safe systems. It must also be guaranteed that this will not be followed by any
automated operations to maintain the steam supply.
To shut the gland steam condenser down, proceed as follows:
 discontinue the steam supply at the steam inlet piece,
 after a wait time of ten (10) minutes, shut off the radial fans, and
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Operation Manual
 discontinue the cooling water supply.

Whether or not the gland steam condenser module will have to be drained will depend on the ambient
conditions. Here, specifically the ambient temperature is critical. The equipment will have to be drained if
there is a risk of the fluids (viz. the condensate and cooling water) beginning to set, solidify or freeze.
Whenever the ambient temperature TU is below or equal to zero degrees Celsius, the pipes and gland
steam condenser module will have to be completely drained.
Draining of water: ambient temperature TU ≤ 0 °C
As a basic principle, the processes must be coordinated with the overriding overall system when the
gland steam condenser module is shut down.
7. Safety regulations
These safety regulations are valid in connection with installation and operation instructions as mentioned
before and are to be observed strictly.
Operating personnel Be aware that all inspection, installation, maintenance and operation works are
performed by qualified personnel.
Personnel with a lack in technical knowledge related to the delivered unit must
be trained and instructed. If required, this instruction can be ordered by the
manufacturer / supplier.
The customer is responsible to train and instruct the operating and
maintenance personnel for the delivered. The customer has to guarantee, that
the operating and maintenance personnel is able to understand the content of
this installation and operation manual.
Dangers by non- Personnel, environment and machinery may be harmed by mechanical,
observance of safety thermal and/or chemical hazards.
regulations Malfunction or breakdown of the gland steam condenser unit or the whole
plant may occur.
The operation of the gland steam condenser unit beyond the specified process
data limits is strictly forbidden.
Safety at work Additional to this manual, national regulations regarding health and safety
have to be followed.
All hot (> 50°C) and cold (< 10°C) parts may inflict thermal damages and have
to be protected or insulated.
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Operation Manual
Inspection, All works on the unit have to be performed after shut-down and cool-down.
installation and Prior working on pressure loaded or vacuum loaded parts all remaining
maintenance pressure or vacuum must be eliminated / vented.
Only genuine or authorized parts are to be used for the maintenance.
All control devices and safety equipment must be reinstalled and put into
operation directly after finishing the maintenance.
8. List of Parts
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1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24
MAM65AN120-M01
M
A A
MAM50AA510 MAM50AA520 WASTE STEAM
MAM65
FAN
MAM50 BR020
BR010
MAM65AN120 MAM65AA520
MAM65AA020
MAM50AA010
MAM50AA020
MAM65
BR005
MAM65AA005
MAM65 02
B B
C
S
MAM65AN110-M01
H M
WASTE STEAM
Even without a label, or with the label "AL: N" oder "ECCN: N", authorization may be required due to the final end-used
when being export out of the EU. Goods labeled with "ECCN" not equal to "N" are subject to US reexport authorization.
MAM50
MAM50
BR010
BR020
MAM65 FAN MAM65
BR010 BR030
MAM65AA010 MAM65AN110 MAM65AA510 3"

Goods labeled with "AL" not equal to "N" are subject to European or German export authorization
MAM50
BR630
C C
MAM65
BR620
MAM50
BR030
LKZ: N
MAA10
MAM50 03 MAM65
BR610
S
C
and destination for which the goods are to be used.
ECCN: N
MAM50
MAW40
BR030
BR620
MAM50
BR610
MAW70 01
MAM50 01
C
S
D S D
MAM50 02
C
MAM65
BR010
PS = bara
TS = °C
TIA S
C
AL: N
C MAW40CT910
S TISCZA
MAW40CT910 MAW70 MAW70
R&I diagram steam system
BR010 BR020
0-06420-BB2284A-00
MAW40
TE TE
BR020
MAW70AA110 X1-IK-200-PRS-PID-00008
MAW40CT010 MAW40CT012
LCA10 03
PI X1
C
S
MAM60CP510
E TE E
LCA10AA310
MAW40CT011
TI
PIA
LCA10 07
LCA10CT520
PS = bara
LCA10 02
MAW40CP010
C
S
C
TS = °C
Max. OPERATING DATA
C
S
LCA10 05
PICA S
C
S
MAW40
15.20 barg 41.8 °C kg/s
BR611
min. 10xDN
MAW40CP010 LCA10
PT
3" P&I diagram condensate system
BR001
MAW40CP010 0-06420-BB2284A-10
LCA10AA710 TS = 60.0 °C X1-IK-210-PRS-PID-10001
TI PS = 27.05 barg
MAW40AC010
LCA10 01
TIA PIA MAW40AA810
WASTE STEAM LCA10CT510
C
S
MAW10CT201 MAW10CP201 MAM60AC010
C
TISA PISA S CONDENSER LCA10
F F
3"
kann sich eine Genehmigungspflicht, unter anderem durch den Endverbleib und den Verwendungszweck der Güter, ergeben.
P&I diagram condensate system

MAW10CT201 MAW10CP201 BR002
MAW40
S
BR810
0-06420-BB2284A-10
TE PT C
TS = 60.0 °C
MAW20 02
LCA10AA610 X1-IK-210-PRS-PID-10001
bzw. deutschen Ausfuhrgenehmigungspflicht. Die mit "ECCN" ungleich "N" gekennzeichneten Güter unterliegen
MAW10CT201 MAW10CP201 PS = 27.05 barg

der US-Reexportgenehmigungspflicht. Auch ohne Kennzeichen, bzw. bei Kennzeichen "AL: N" oder "ECCN: N"
C
S
Max. OPERATING DATA
Die mit "AL" ungleich "N" gekennzeichneten Güter unterliegen bei der Ausfuhr aus der EU der europäischen
MAW40
LCA10 06
Max. OPERATING DATA
LCA10 04
1.03 bara 480.0 °C kg/s
C
S
BR010
C
S
MAW10 01
15.28 barg 40.6 °C 9.17 kg/s
1"
C
S
TS = 499.0 °C MAM60AA010 MAM60AA030
PS = 7.00 barg MAM60AA020
Max. OPERATING DATA 2" S
MAM60 08
MAW40
BR610
10.25 bara 485.0 °C 0.13 kg/s C
C
S
MAM60
MAW10 MAW20AT010 MAW30 3" BR010
P&ID Auxiliary Steam
LKZ: N
BR010 BR010 MAM60 01 0-06420-BB2284A-10

MAW40 01 MAW40 03 TS = 90.0 °C
G X1-IK-200-PRS-PID-00011 G
X1-IK-210-PRSS-PID-10002 TS = 505.0 °C free flow PS = 0.50 barg
PS = 10.80 barg <2m <1m S S X10
MAW20AA010 MAW20AA110
C C Emergency overflow
mech. design
ECCN: N
MAW10AA110
H H
AL: N
H
external drain system
Max. OPERATING DATA
n
7.00 barg 40.0 °C kg/s
o
Air Supply
i
external
s
TS = 65.0 °C
i
PS = 11.00 barg
J J
v
Legend of Symbology:
e
local (in field)
r R Turbine Control System (TCS)
f f ü Local control system (black box)
LCE30
BR020
K K
Distributed control system (DCS)
wu
t
Symbology acc. to DIN; DIN EN ISO; DIN EN
n
express authorization are prohibited. Offenders will be held liable for payment
of damages. All rights created by patent grant or registration of a utility model
well as utilization of its contents and communication thereof to others without
Transmittal, reproduction, dissemination and/or editing of this document as
E
Battery limit Customer connection
no....
C
C
S
S
LCE30 02
S = Siemens S = Siemens
C
L L
S
C = Customer C = Customer
LCE30 01
C
S
or design patent are reserved.
Max. OPERATING DATA

15.28 barg 40.9 °C kg/s Pipes symbology:
LCE30 Steam-air
BR001
0-06420-BB2284A-10
X1-IK-200-PRS-PID-00011 TS = 60.0 °C Air
PS = 27.05 barg LCE30AA110
C LCE30AA010
LCE30AT010 Gland steam
M M
D15
X1-IK-200-PRS-PID-00009
0-06420-BB2284A-01
P&I diagram drain system
N N
CONSORTIUM DWG. NO. :

X1-IK-200-PRS-PID-00010
For Sulut X = "S"
P
For Timor X = "T" P
Code Word: SULUT / TIMOR

Schadenersatz. Alle Rechte für den Fall der Patenterteilung, Gebrauchsmuster-
Weitergabe sowie Vervielfältigung, Verbreitung und/oder Bearbeitung dieses
Project No.: BB002284 / BB002285

Dokumentes, Verwertung und Mitteilung seines Inhaltes sind verboten,
soweit nicht ausdrücklich gestattet. Zuwiderhandlungen verpflichten zu
G 2021-02-15 Koppeel Guretzka Guretzka see Rev.-Index
Timor Sulut Rev.

Rev.
Blatt
Sheet
Entstanden aus:
Koord.
Coordin.
Datum
Date
erstellt
Prepared
mit Änderung:
bearb.
Checked
geprüft
Approved
Änderungsbeschreibung
Description of Change
1720-000006000E
Turbine 1 Turbine 2 Turbine 1 Turbine 2
Original of: with Revision:
Datum Name Maßstab
1:1 Specification: Norm
oder Geschmacksmustereintrag vorbehalten.
Date Name Scale

erstellt Benennung
2020-01-24 Koppeel
Title
P&I diagram Gland steam system
KKS-PREFIX 11 12 11 12
Prepared
bearb.
2020-01-24 Guretzka
Checked
Q geprüft
Approved
2020-01-24 Guretzka R&I-Fließbild Sperrdampfsystem Q
KKS 11 MAA10 12 MAA10 11 MAA10 12 MAA10 SIEMENS energy CAE
Format Ident-Nr./Unterlagen-Nr. Rev. Spr. Blatt
Gas and Power Size Ident-Number/Document-Number Rev. Lg. Sheet
SIEMENS No. BB002285A BB002285B BB002284A BB002284B A0 0-06420-BB2284A-02 G de en 1/1
Protection class: Restricted © Siemens Energy, 2020

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24
4. Installation- and safety instructions

4. Montageanleitung / Sicherheitshinweise
Commission-N°:
7001021687
Factory-N°:
4020004 Project:
TIMOR 1
Drawing-N°:
BB2285A
Baujahr: Pos.-Nr.:
2021 Pos.-N°.:
--
Installation: Only designed lifting lugs and -plugs are used to lift and transport of apparatus
respectively the unit.
It is inadmissible to use fixed prunings to lift!
The specified empty weight on the name plate is to observe when lifting!
The apparatus/ unit only lift and transport in empty condition!
The apparatus/ unit is to couple at foundation/ steel construction immediately
after installation.
Foundations respectively steel construction must meet structurally the requirements
for the installation! For it the maximum weight of apparatus/ unit in filled condition is
to be taken from the drawing respectively this operating instruction.
At installation it is to be provided for enough expansion space for inspections and
maintenance.
Mounting/ Piping: At connecting of pipeline do not overshoot the allowed nozzle load given on drawing!
Indicated starting torques for flange connectings are to be kept!
The extended pipeline must have the same rated pressure stage like apparatus-/
unit nozzles self.
Use only seals, which resist operating conditions as well as the medium!
Operation: Before starting a tightness check must be carried out!

Do not overshoot respectively undershoot the allowed upper limit and lower
limit for working pressure and working temperature!
Opening of inspection orifices or dismantle of pipelines are carried out only
in depressurized conditions respectively unit standstill! In every case a release
have to be overtaken by an appropriate pass note by operator.
Apparatus/ unit may be operated only with media for which it is designed.
Only authorized persons should serve mounted fittings.
Maintenance/ Inspection: The essential inspection intervals have to be kept. These are prescribed for
operator by control equipment!
5. Lagerungshinweise
5. Storage instructions

Commission-N°:
7001021687
Factory-N°:
4020004 Project:
TIMOR 1
Drawing-N°:
BB2285A
Baujahr: Pos.-Nr.:
2021 Pos.-N°.:
--
Lagerung: Die Lagerung muss in einem unbeheizten und trockenen Lagerraum erfolgen!
Es ist darauf zu achten, dass die Anschlussstutzen bis zur Montage der
Anschlussrohrleitungen verschlossen bleiben, um ein eventuelles Eindringen von
Feuchtigkeit auszuschließen.
Der Transport zum und vom Lagerplatz ist mit den dafür geeigneten Transportmitteln
vorzunehmen.
Das Anheben der Anlage darf nur über die dafür vorgesehenen Tragösen erfolgen.
Storage: The storage have to occur in a unfired and dry depot.

Connecting nozzles have to be closed until installation of the connecting pipelines,
because it have to be excluded a entry of dampness.
The transport to and from storage is made with suitable means of transport.
The elevate of the unit may occur with allowed hitches.
Lagerung
im
Gebäude
storage
in
a hall
6. Leckdampf-Kondensator
6. Gland Steam Condenser

Commission-N°:
7001021687
Factory-N°:
4020004 Project:
TIMOR 1
Drawing-N°:
BB2285A
Baujahr: Pos.-Nr.:
Year of manufacture: 2021 Pos.-N°.: --
Komponente: Leckdampf-Kondensator 11MAM60AC010

component: Gland Steam Condenser
Zeichnung 65-2432X - Rev. 3

1.
Drawing 65-2432X - Rev. 3
Betriebs- und Wartungsanleitung
2.
Operating and Maintenance Manual
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
TECHNISCHE DATEN / TECHNICAL DATA
Vorschriften:
Abnahme:
Inspection by
A DESIGNER: ANA Prozesstechnik GmbH A

MANUFACTURER: AEL Apparatebau GmbH Mantelseite Rohrseite
max. zul. Druck min. / max. bar Ü
1445 [1444] max. allowable pressure PS
-1 / 0,5 0 / 27,05 bar g
N3 max. zul. Temperatur min. / max.
Allowable working temperature TS 5 / 325 5 / 60 °C
N3 N4 N4 bar Ü
322 [325] 2 750 373 [372] 2 Verfahrensdruck
Operating pressure -0,01 ... 0 15,2 ... 15,3 bar g
N6 Verfahrenstemperatur 67,2 ... 237,2 40,8 ... 41,8 °C
Operating temperature
N6 N6 mit Wasser 20°C - Lage horizontal
175 225 Prüfüberdruck 3,0 36,5
116 [118]
116 [118]
testing pressure with water 20°C - horicontal position PT bar Ü
bar g
121 mit Luft (Leckagetest)
2
N/A N/A
2
with air (leakage test)
N8
200
Inhalt gesamt
volume total
15,0 7,6 l
Wärmeaustauschfläche 1,37
410 [411] 2
2
m
n168.3
B Heat exchanging area
Fabrik-Nr.
B
Factory-No. 301 542 ; 3120002
N1 N2 FS Baujahr
Year of construction 2021
Medium Luft, Dampf Kühlwasser
2 medium air, steam cooling water
176
gasförmig flüssig
200
Aggregatzustand
210
116 [118]
N7 A A B B Dichte
density
0,53 ... 980 992 ... 993 kg/m
3
toxisch / brennbar / explosiv NEIN / NO NEIN / NO

175 225 Fluidgruppe
Fluid group
-- --
322 [325] 2 T1 T2 N7 N5 Schweissnahtfaktor
N5 N7 Korrosionszuschlag
520 555
C Längsnähte C
Röntgen / U.S.-Pruefung Long. welds
der Schweissnähte Rundnähte
Circ. welds
X-ray / ultrasonic testing
of welds T-Stoesse
T-joint
Andere Prüfungen siehe Schweiß- und
Other tests Prüfplan
in acc. to welding and test plan
Schweissverfahren 247 783
Welding process
Vorwärmung ja/nein
Pre-Heating yes/no
1445 Wärmebehandlung ja/nein
Heat treatment yes/no
Insulation warm/cold -- mm
D Auskleidung
D
Lining -- mm
Oberflächenausführung aussen gemäß ANA Anstrichkonzept
Abmaße und Toleranzen nach DIN 28008, Genauigkeitsgrad AR Surface finish outside
measurements and tolerances acc. DIN 28008, grade AR
acc. to ANA painting concept
N1 N2 Vor dem Versand ist der Wärmetauscher von inneren und äußeren
Gewicht
Verunreinigungen zu säubern und zu entleeren. Weight 100 kg
prior to shipping the vessel must be free from impurities and Gewicht mit Wasserfüllung
Weight full with water 122,6 kg
residues and all internal parts must be drained Betriebsgewicht
operating weight 115 kg
324 Bemerkungen
Remarks
Allgemeintoleranzen: für Schweißkonstruktionen - EN ISO 13920 Klasse-B+F ; Lastspiele ≤ 500 ( gem. ASME Sec.VIII )
E general allowances: for welding construction - EN ISO 13920 class-B+F; load application ≤ 500 ( acc. to ASME Sec.VIII ) E
FS
N8
A-A ( 1 : 5 ) B-B ( 1 : 5 ) N6
N4
N2
120
120
R9
F .25 F
60 n18.5 45 40
N3
SUTZENTABELLE / table of nozzle
Bez. Anz. Benennung DN Standard Dichtfläche Rohrabmessung Bemerkung
designation Class
des. no. NPS standard gasket surf. dimens. of tubes remarks
Kühlwassereintritt Firmenschild / name plate N6
N1 1 3" 300 ASME B16.5 RF Ø88,9x5,49 3" STD Maße in [...] sind Ist-Maße
cooling water inlet N7 measures in [...] are actual size
Kühlwasseraustritt MADE IN GERMANY
N2 1 3" 300 ASME B16.5 RF Ø88,9x5,49 3" STD Hersteller/ Manufacturer
cooling water outlet ANA PROZESSTECHNIK GmbH
G
N3 1
Brüdeneintritt
vapor inlet 3" 150 ASME B16.5 RF Ø88,9x5,49 3" STD ANA-Kommission
ANA-Commission
Herrfurthstraße 9
06217 Merseburg
F220-3511-002 AEL APPARATEBAU GmbH

T2 AEL-Nr.: 3120002 G
Brüdenaustritt Benennung
gland steam condenser 5

N4 1 3" 150 ASME B16.5 RF Ø88,9x5,49 3" STD Designation
vapor outlet geltende Normen 4

applicable norm
3
Kondensataustritt AEL-Fabrik-Nr.
301 542 ; 3120002 Baujahr
2021 Lochstellung von asbuilt [...]
N5 1 3" 150 ASME B16.5 RF Ø88,9x5,49 3" STD AEL-Serial No. Year built 2 16.02.2021 TTE SMI
condensate outlet Mantelseite / shell side Rohrseite / tube side Flanschen, wenn nicht

1 11.12.2020 Gö Ga Ga Schweißtechnik
m. Verschlussschraube min./max. allowed pressure
[PS] 5 / 325 bar g -0,01 ... 0,0 bar g anders angegeben 0 09.11.2020 TTE SMI Erstausgabe / first issue
N6 2 Entlüftung ventilation 1/2" -- AELS 2851 -- -- min./max. zulässige Temperatur
[TS] 5 / 60 °C 15,2 ... 15,3 °C T1 Position of flange
with screw Prüfdruck unless otherwise
Zust.
Rev.
Datum
Date
erstellt
drawn
geprüft
checked
genehmigt
approved
Bemerkungen
Remarks
[PT] 3,0 bar g 36,5 bar g
Test pressure
Entleerung emptying -- -- -- m. Verschlussschraube Inhalt [V] N1 stipulated
N7 2 1/2" AELS 2851 Volume 15,0 l 7,6 l
Benennung / Description:
with screw
Messstelle
Leergewicht
Empty weight
Betriebsgewicht
Operating weight
FS http://www.ana-gmbh.com
e-mail: [email protected]
N8 1 pressure measurement 1/2"
-- AELS 2851 -- -- --
Prüfdatum
100 kg 115 kg
N5 Herrfurthstrasse 9 * D-06217 Merseburg
gland steam condenser
Monat/Jahr
Test date Month/Year Tel.: 03461/457-0 * Fax: 03461/457-200
Festlager -- -- -- -- -- --
H T1 1 Bei Ersatzteilbestellung Fabrik-Nr.und Baujahr angeben. Fertigungsauftrag-Nr.: Blattgröße: Maßstab: Zeichnung-Nr. / Drawing-No.:
fixed saddle When ordering spares, please state serial no. and year built. N7 Production order-No.: Sheet Size: Scale:
Rev.
Zust.
H
T2 1
Loslager
-- -- -- -- -- --
F220-3511
(14 487/2020)
A1 1:5 65-2432X 2
sliding saddle
Werkstoff / Material: Hierzu / To this: Kunde / Customer: Siemens Gas & Power GmbH & Co. KG
Firmenschild shell side: Gr.B bolts/nuts/gasket: --
FS 1 -- -- -- -- -- 120x120x75 65-2432 Projekt / Project: Timor 1
name plate tube side: TP316L tube sheet: TP316L Bestell-Nr. / Order-No.: 7001021687
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
Deckblatt / Cover sheet
- Montageanleitung / installation manual

- Inbetriebsetzungsanleitung / start-up manual
- Betriebs- und Wartungsanleitung /
operation and maintenance manual
Customer: ANA Prozesstechnik GmbH

(Siemens Global Energy GmbH & Co. KG)
Standort / location: Deutschland

Bestell-Nr. / Order-no.: B221-18214-3511
Projekt-Nr. / Project-no: -
Projekt Kennwort / Project code word: TIMOR 1
Manufacturer: AEL Apparatebau GmbH Leisnig

Döbelner Straße 9
04703 Leisnig
Benennung / denomination: Gland Steam Condenser
Projekt / project: TIMOR 1
AEL Kommissions-Nr. / job no.: 3120002
AEL Zeichnungs-Nr. / drawing no.: 65-2432X
Ident-Nr. / ident no.: 1203.100601
Baujahr / year of manufacture: 2021
Allgemeine Dokumentation für

Rohrbündelwärmeübertrager
00 Erstausgabe / First issue 03.06.21 Böttger Stollberg General documentation for

Rev. Beschreibung Datum erstellt geprüft Shell- and tube heat Exchangers
Description date designed check
Kunde / customer Format
size
A4
ANA Prozesstechnik Dok.-Nr. / Blatt / sheet Rev.
GmbH doc no.:
1 von 24 / 00
1 of 24
Content
1 Preliminary Remarks ........................................................................ 3

1.1 General Information ........................................................................................................................ 3
1.2 Safety Information............................................................................................................................ 4
1.2.1 General Information ............................................................................................................... 4
1.2.2 Selection and Qualification of the Personnel.......................................................................... 5
1.2.3 Warning Notices and Safety Symbols .................................................................................... 6
1.3 Exclusion of Liability ....................................................................................................................... 7
2 Installation Manual ........................................................................... 8
2.1 Scope of Installation ......................................................................................................................... 8
2.2 Prerequisites...................................................................................................................................... 8
2.3 Necessary Tools and Aids ................................................................................................................ 8
2.4 Performance of Installation ............................................................................................................. 9
2.4.1 Transport and Storage ............................................................................................................. 9
2.4.2 General Installation Information........................................................................................... 10
2.4.3 Installation Manual ............................................................................................................... 10
2.5 Recording – Installation – Inspection Sequence Plan ................................................................. 12
3 Operational and Thermal Design Data ......................................... 12
4 Start-up Manual............................................................................... 14
4.1 Media and Material ........................................................................................................................ 14
4.2 Start-up............................................................................................................................................ 14
4.3 Operation......................................................................................................................................... 16
4.4 Troubleshooting .............................................................................................................................. 17
5 Repair Work and Maintenance Instructions ................................ 18
5.1 Shutdown ......................................................................................................................................... 18
5.2 Disassembly ..................................................................................................................................... 18
5.3 Cleaning ........................................................................................................................................... 19
5.4 Maintenance .................................................................................................................................... 20
5.5 Options of Repair ........................................................................................................................... 21
5.6 Reassembly / Pressure Test............................................................................................................ 21
5.7 Restart ............................................................................................................................................. 22
5.8 Operation......................................................................................................................................... 22
5.9 Spare and Wear Parts .................................................................................................................... 22
5.10 Service AEL .................................................................................................................................... 23
6 Annexes ............................................................................................. 24
6.1 Annexe 1: Forms for the Recording Repeated Pressure Test..................................................... 24
1 Preliminary Remarks
Inhalts sind verboten, soweit nicht ausdrücklich gestattet. Zuwiderhandlungen verpflichten
Weitergabe sowie Vervielfältigung dieses Dokuments, Verwertung und Mitteilung seines
1.1 General Information
This manual shall necessarily be submitted for the attention of the operating personnel before
start-up, maintenance and repair.
a) The following instructions are based on the theoretical and practical experiences of the
manufacturer.
b) The instructions alone cannot, of course, contain a complete description of the operation of
the tube bundle heat exchanger and of all possible safety measures. In the case of doubts
relating to the operation of the tube bundle heat exchanger and safety measures related to it
the manufacturer is at the disposal of the plant owner/plant operator until the end of the
warranty period.
c) The manufacturer recommends to the owner/operator of the plant to train the operating
personnel according to these instructions and to ensure that these personnel have understood
the information and safety measures obtained and that it will respect them.
d) This plant shall be operated and maintained only by well-trained and responsibly qualified
personnel.
zu Schadenersatz.
e) These instructions shall not affect the responsibility of the plant owner/operator for the
operation and the safety of the tube bundle heat exchanger/s.
f) In any case the owner/operator of the plant has to comply with the relevant and legally
applicable public regulations, recommendations and guidelines and/or with those of
professional associations (environmental protection, accident prevention and/or safety
measures for the worker etc.).This also applies if individual provisions, standards and
guidelines are not mentioned herein. Order-related specifications (if any) shall also be
The copying, distribution and utilization of this document as well as the communi-
cation of its contents to others without expressed authorization is prohibited. Of-
observed.
g) During the warranty period, repair or modification work on the tube bundle heat exchanger
shall be carried out exclusively by the service personnel of the manufacturer or, only after a
prior written approval by the manufacturer, by the personnel of the plant owner/operator or
by third parties.
h) The operator shall by means of appropriate safety installations ensure that an overstepping
fenders will be held liable for the payment of damages.
both of the operating conditions indicated on the factory nameplate/the drawing and of the
permissible load changes of the tube bundle heat exchanger will be precluded.
i) In the case of any changes to the operating data or modifications of the tube bundle heat
exchanger without written approval of the manufacturer all responsibility of the manufacturer
related to the tube bundle heat exchanger shall cease.
j) The manufacturer does not assume any warranty obligation and/or responsibility for damages
resulting from the failure to observe this instruction.
k) The manufacturer cannot be held liable for indirect or consequential damages.
l) The manufacturer does not assume any responsibility for the deterioration of any parts or of
any equipment component caused by corrosion, erosion, improper operation or other reasons,
no matter when such defects occur after the leaving of the manufacturer’s factory workshop,
with the exception of the warranty claims stated in the contract.
AEL Apparatebau GmbH Leisnig Page 3 / 24

General Operation and Maintenance Manual Rev. 0
m) In the case of warranty claims the manufacturer reserves the right to request the fully
completed installation inspection sequence plan (see installation manual), the completed
record of repeated pressure tests (if already carried out during this period) as well as the
complete documented evidence that the following indications which form the basis of the
construction have been respected during the operating period:
- parameter of the data sheet, see point 3 (e.g. pressures, temperatures, throughputs,
media),
- temperature changing speeds (max. 5 K per minute),
- pressure changes speeds (The pressure increase permissible per time unit when there is
pressure stress shall not exceed 0.5 bar per minute).
n) In the case of a discrepancy within this document the manufacturer shall be contacted
immediately. The German version of this document is to be considered as the legally binding
version; it is available at the manufacturer and can be delivered at any time.
o) If in the document there is reference made to “drawings”, always the apparatus specific
drawings listed in point 6.3 shall apply. Other drawings are stated separately.
1.2 Safety Information

zu Schadenersatz.
1.2.1 General Information
a) The tube bundle heat exchanger shall not be used for other purposes than those it is intended
for. In the case of use not compliant with the intended use the liability of the manufacturer
expires.
b) When working with media which are hazardous/harmful to health, e. g. hot media, irritant
media, inert gases at transportation fillings, the relevant provisions and sets of rules shall be
complied with. The hazard area shall be indicated.
c) Leakages, leaked or spilled fluids shall be removed immediately and shall be disposed of
properly. The hazard area shall be indicated.
d) The operating personnel shall regularly be advised of special hazards and there shall be
trainings on how to deal with these hazards.
e) It is recommended to wear helmets and non-slip working protective shoes.
f) Generally, the work on the tube bundle heat exchanger is only allowed in the depressurized
state and at temperatures excluding any damage to health. As the case may be the tube
bundle heat exchanger may be drained. The tube lines leading to the tube bundle heat
exchanger shall be blocked.
g) During the whole operating time of the tube bundle heat exchanger order and cleanliness
shall be observed. This applies especially to controls and instruments which need to be fully
functional and good to read at any time. When loose parts or tools are left this may cause
severe dangers - so this shall absolutely be avoided.

h) Plant components whose surface temperature may rise up to above 60 °C during operation
shall be marked in a clearly readable manner with the sign “Hot Surfaces” or shall be
isolated in the appropriate way. The warning notices are always to be kept clean and
completely and well readable.
i) Should there be inadmissible high vibrations during operation the reason therefore shall be
identified immediately and as the case may be may be eliminated in consultation with the
AEL Apparatebau GmbH Leisnig. If these vibrations cause a clearly identifiable danger to
persons, the apparatus and the environment, the tube bundle heat exchanger must be turned
off in a controlled way as described in this operation manual.
1.2.2 Selection and Qualification of the Personnel
The personnel for the operation, maintenance, transport and storage needs to have the
appropriate qualification which is relevant for the works to be carried out. The scope of
responsibilities, competences and supervision of the personnel must be clearly regulated by the
operator. If the personnel do not have the required knowledge it shall be trained and instructed
accordingly before the first start-up. If necessary and by order of the operator of the tube bundle
heat exchanger, this may be carried out by the manufacturer/supplier. Furthermore, the operator
shall ensure that the operation and installation manuals are read completely and that their
zu Schadenersatz.
contents are understood.
Furthermore, all persons who carry out works in relation to the tube bundle heat exchanger shall
meet the legal provisions such as the required minimum age, and they must not be under the
influence of mind-altering substances such as medicines, alcohol or drugs.

1.2.3 Warning Notices and Safety Symbols
The warning notices and safety symbols attached by the operator of the tube bundle heat ex-
changer shall be observed.
The safety notices contained in this installation manual which may, in the case of non-
observance, cause dangers to persons, shall be marked with a general danger symbol
safety symbol according to DIN 4844 – W 9,
Electrical voltage warnings shall be marked with the

zu Schadenersatz.
or shall be labelled with the word
CAUTION!
observance, cause dangers to the machine or malfunctions additionally contain the word
CAUTION.
Notes directly attached on the machine, e. g.

- rotation direction arrow
- markings for fluid connections
- warnings of hot surfaces
- warning of hand injuries
- lift only with crossbeam / lifting point
shall absolutely be observed and kept in a completely readable state.
The existing national and international regulations on accident prevention as well as possible
internal company regulations on work, operating and safety shall apply in parallel with the safety
notices stated in this installation manual

Failure to comply with the safety notices may cause dangers to persons, the environment and the
machine. Furthermore, failure to comply with the safety notices results in the loss of any claim
for damages against the manufacturer.

In detail, the non-compliance may result for instance in the following dangers:
- danger to persons because of electrical, mechanical and chemical influences
- failure of important functions of the machine/plant
- failure of the prescribed methods of maintenance and repair
1.3 Exclusion of Liability
The AEL Apparatebau GmbH Leisnig cannot assume any responsibilities for damages resulting
from the failure to observe these installation, operation and maintenance manuals and the docu-
ments included therein.
Also excluded is any liability of the AEL Apparatebau GmbH Leisnig for damages caused by a
use other than the intended use and by unauthorised structural modifications at the tube bundle
heat exchanger. This also applies to damages which could have been prevented by a regular
monitoring of such parts subject to wear and by timely and proper repair works.
zu Schadenersatz.
In addition, AEL Apparatebau GmbH Leisnig assumes no liability for any damage arising from
events of force majeure or from external interference.
During the guarantee period repair and modification works on the machine that may become
necessary shall be carried out exclusively by our service personnel or, after our prior written
approval, by the operating personnel or third parties.
Original spare parts and accessories authorized by the manufacturer serve to enhance safety. The
use of other parts may annul the liability for the consequences resulting therefrom.

2 Installation Manual
2.1 Scope of Installation
 Installation of the tube bundle heat exchanger/s

 Connecting the tube lines
 Installation of the measuring instruments, if any
 Installation of the isolation, if any
 Grounding
 Recording (see point 2.5)
2.2 Prerequisites
 Completeness of the delivery according to the shipping list of items

 Prepared, vertical, flat and sufficiently dimensioned base / framework with anchor screws,
respectively steel construction with bolted connections
 Qualified installation personnel
zu Schadenersatz.
 Accessibility to the place of installation for transport vehicles and hoisting gears
 Sufficiently fixed ground for transport vehicles and hoisting gears
2.3 Necessary Tools and Aids
 Hoisting gears (e. g. crane) and sling gears for installation

(weight indications see drawing No. on cover sheet)
 Levelling device for the alignment of the tube bundle heat exchanger/s
 Screw tightening device with torque adjustment and indication

 Diverse tools (screw wrench, screw driver etc.)
 Platform of framework for the installation of the tube pipes and the controls
 Detergent and cleaning agents

2.4 Performance of Installation
2.4.1 Transport and Storage
a) In the context of a construction and first pressure inspection at the manufacturer's works with
the required inspection pressures (see drawing No. on cover sheet) the tube bundle heat
exchanger has been checked for flawless leak tightness.
b) Attention must be paid to ensure that damage caused by external influences is excluded
during transport, storage and installation. The tube bundle heat exchangers shall be stored
correctly, at a dry place, under a roof or carefully covered. All openings shall be closed.
c) For the transport on the building site the ground should be stabilized by means of crushed
stone, gravel bedding and concrete slabs and accessible for vehicles and hoisting gears.
d) The slinging for transport shall be carried out at the attachments points provided for this
purpose. When using carrying devices such as belt straps the corresponding safety
regulations and guidelines of the country in which the apparatus is installed shall be
observed.
e) Tube bundle heat exchangers of a horizontal installation type shall be placed on the saddle
bearings, vertical/standing tube bundle heat exchangers on the legs, the wooden slide or the
zu Schadenersatz.
like. Attention shall be paid to ensure that the diverse attachment parts (nozzles, steel
construction clips and the like) are not used for hoisting, that they do no touch the ground or
are not damaged in any other way.
f) To protect the coating bare steel ropes or chains are not permissible for the transport. When
using suspension ropes it shall be ensured that these ropes are secured against slipping
g) If the tube bundle heat exchangers are filled with nitrogen (e. g. p=0.5 bar (g)), the nitrogen
shall be discharged completely at the fixed shut-off valve prior to the installation and in
compliance with the relevant safety requirements (suffocation hazard).
h) The cover lids attached when leaving the manufacturer’s works shall be removed only
shortly before installation and only from the depressurized apparatus.
i) If the scope of delivery includes spare seals, special care shall be taken during their transport
and storage in order to prevent damages. Depending on their size, the seals are fixed in
boxes, cases or on cardboard papers and shall always be transported in a horizontal state
(manufacturer's instruction) in order to prevent that the coatings (e .g. graphite in the case of
grooved gaskets) peel off from the base material.

2.4.2 General Installation Information
a) Installation of the tube bundle heat exchanger/s according to the installation plan of the plant
operator.
b) Tube lines and shut-off devices shall be mounted without any tension. It shall be ensured
that, also during the operation, no inadmissible tensions, forces, torques and vibrations are
transferred to the tube bundle heat exchanger. All tube line connections must be mounted.
c) For the tube line connection pay attention to the inlet and outlet sides. The tube line routing
is laid according to the tube line plan of the plant operator.
d) The tube bundle heat exchangers shall be safely anchored in the base and at the framework
respectively.
e) In order to compensate thermal expansions of horizontal tube bundle heat exchangers the
slide bearing shall be anchored in way that allows for the necessary sliding movement
without restrictions.
f) For the integration of the anchor screws of standing tube bundle heat exchangers into a base
the base ring template included in the delivery shall be used if agreed.
g) In the case of tube bundle heat exchangers of the construction type with screwed or welded
zu Schadenersatz.
floating head and U tube bundles, there shall be - on the fixed head tube sheet side - a free
space of the length of at least the length of the tube bundle, if the tube bundle shall be pulled
at the place of installation. Moreover, enough space shall be provided for the removal of the
hood/chambers. Where applicable, the pivoting range of the installation and disassembly
equipment (pivot arms, hinges) shall be kept free.
h) In the case of tube bundle heat exchangers with compensator protection this protections shall
be removed in order to ensure the mobility (expansion compensation) of the heat exchanger
in the operating mode.

i) If there are any adsorbents such as gel pouches, transport and nozzle locks, all of them shall
be removed.
j) If a tube bundle heat exchanger is not put into operation for a longer period of time (approx.
half a year), a renewal of the seals is recommended especially for the soft-material gaskets.
k) Opened flange connections shall be equipped with new seals before the reinstallation -
after the cleaning of the sealing surfaces and the possible elimination of damages. The
installation of seals must be carried out with the utmost care. Defect seals shall not be
installed. The thread of screws and nuts shall be treated with an appropriate lubricant.
l) All flange connections shall be equipped with the number of screws indicated on the
drawing, to be tightened cross wise and clockwise progressing over the whole
circumference.
m) In order to prevent electrostatic charging the tube bundle heat exchangers shall be grounded
(grounding points see drawing No. on cover sheet).
2.4.3 Installation Manual

a) All tube bundle heat exchangers and accessory parts have been labelled at the
manufacturer’s premises. The parts included in the delivery shall be checked for
completeness with the shipping list of items and the list of loose parts.
b) The construction components and connecting elements necessary for the installation of the
tube bundle heat exchangers shall be taken out and laid out according to the installation
sequence.
c) Horizontal (lying) tube bundle heat exchangers:
Adjustment and screwing of the lower saddle bearings on the base
The tube bundle heat exchanger stands on at least two saddle bearings. The allocation of
fixed bearing and slide bearing is indicated on the drawing.
In order to compensate the thermal expansions of horizontal tube bundle heat exchangers
the other slide bearing shall be anchored in way that allows for the necessary sliding
movement without restrictions. It shall be observed that a sliding plate, which may exist,
is installed between the base and saddle bearing.
Vertical tube bundle heat exchangers:
Vertical tube bundle heat exchangers may be designed upright (e. g. by means skirt
support) or suspended (e .g. by means of support claw, support ring). In order to
compensate the thermal expansions the fastening must be carried out in an appropriate
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way (e. g. with counter nut), to allow for the movement in horizontal direction.
Furthermore, as a consequence of thermal expansion it must be ensured that there is
enough free moving space in vertical direction.
d) Screwings and flange connections shall be tightened cross wise and clockwise, progressing
over the whole circumference. The thread of all screws and nuts shall be treated with an
appropriate lubricant. Before integrating the seals the sealing surfaces shall be checked for
cleanliness and evenness. Defect seals shall not be installed.
e) The grounding of the tube bundle heat exchangers shall be carried out at the marked parts
(see drawing No. on cover sheet).

f) If the mounting of installation and disassembly equipment (pivot arms, hinges) for the
chambers, covers etc. has not been agreed when ordering the tube bundle heat exchangers, a
suitable accessibility for mobile hoisting gears must be ensured.
g) After completion of the installation works the inspection sequence plan (see point 2.5) shall
be completed and checked for completeness of the inspection results and for signatures. In
the table “Accuracy of Inspection Results” the check must be confirmed by signature.

2.5 Recording – Installation – Inspection Sequence Plan
System / Component: Applicable Installation Instruction No.:
Installation contractor: Annexes:
Scope of inspection Inspected by Inspection result Date / Signature

EC Cl II A
V
Completeness of the delivery, h i i
see packing list
Distance nitrogen filling, gel h

pouch (as far as existent)
Installation and fastening of the h

tube bundle heat exchanger on
the base plate / framework,
Inspection of the adjustment
Inspection of the safety

installations against excessive h
zu Schadenersatz.
pressure
Inspection - check of the

installation of tube lines for h
correct connection to the inlet
and outlet device
Inspection of the tightening

torques of the flange h i i
connections
Grounding of the heat

exchanger/s h i i
Leak tightness test of the tube

bundle heat exchanger in the h i i h
context of the complete plant
h – stopping point(participation in the inspection is absolutely required)
i – information point(information shall be provided prior to the inspection)
For the accuracy of the inspection results

Installation contractor Client Independent inspector(II) Advisor / Supervisor
(EC) (Cl) (AV)
Name
Date
Signa-ture
3 Operational and Thermal Design Data

Pressure chamber Shell Tube
side side
maximum permissible pressure PS -1/0,5 0/27,05

(bar)
min. / max. permissible temperature TS 5/325 5/60
(°C)
volume V 15 7,6
(l)
medium steam, air cooling
water
fluid group according to DGRL 2 2
physical state at operating pressure gaseous liquid
max. permissible number of stress cycles ≤ 500

test pressure PT 3,0 36,5
(bar)
year of manufacture 2021
average wall temperature °C (only for fixed
bundles)
zu Schadenersatz.
Remarks:
Unless otherwise stated, the operation and design data (see drawings) are determined by the
process owner.

4 Start-up Manual
4.1 Media and Material
a) The used materials are carefully selected and determined by the customer/operator. All
provisions of the process owner on the media composition shall be met.
b) The compatibility (appropriateness) of the fluids with the pressure device applications and
with the seals shall be proved by the operator in the context of the inspection prior to the
start-up.
c) Negative effects on the corrosion behaviour and the material resistance resulting from the
effects of additives (e. g. inhibitors) and/or whose usage was has not been approved by the
process owner shall not be at the expense of manufacturer of the tube bundle heat exchanger.
4.2 Start-up
a) The operator shall be responsible for the necessary safety measures. The permissible
operating parameters of the tube bundle heat exchanger/s indicated on the factory nameplate
zu Schadenersatz.
and the drawing must be met and must not be exceeded.

b) Prior to the start-up the transport equipment must absolutely be removed, the fastenings of
the fixed callipers and sliding callipers shall be checked.
c) In the case of flange connections with seals, all bolts of the flange connections shall be
retightened prior to the start-up. The bolts are to be tightened evenly with the tightening
torques indicated on the drawing. The retightening of the bolts shall be carried out cross wise
and clockwise progressing over the whole circumference.
d) Pressure chambers with fluid media shall be vented completely. Especially during and after
the filling repeated venting shall be carried out. The venting state shall be regularly checked.
e) The minimum and maximum values (e. g. pressures, temperatures) stated in the data sheet
(see point 3) shall not be exceeded.
f) In the case of tube bundle heat exchangers with stuffing box, the leak-tightness of the
stuffing box shall be checked continuously until the operating parameters are achieved.
g) Tube bundle heat exchanger with fixed bundles and respectively with stuffing box and
single-flow tube bundle heat exchangers with floating head:
- To avoid inadmissible wall temperature differences, the shell side shall always be started
first and the tube side shall be connected afterwards. When shutting down, the shell side
is to be shut down after the tube side.
h) Tube bundle heat exchangers with floating head (except for single-flow) and U tube bundles:
- At first load with a colder medium, irrespective if in the shell or the tube side.

i) During the start-up of the tube bundle heat exchangers sudden pressure and temperature
changes shall be avoided. The pressure increase permissible per minute when there is
pressure stress shall not exceed 0.5 bar per minute, in this context point 4.2 j) must absolutely
be considered.
j) In order to prevent temperature shocks, cold rooms shall not be suddenly loaded with hot
media and hot rooms shall not be suddenly loaded with cold media. By carefully dosing the
media a slow heating and cooling of both types of media rooms shall be envisaged. 5 K per
minute shall be considered as the maximum guiding value for the heating-up rate. A gradual
heating-up with longer dwell times is recommended.
The winter starting conditions for tube bundle heat exchangers for Russia see annexe 6.1.
k) If there are leakages at the flange connections the tube bundle heat exchanger must be shut
down immediately. Pressure and temperature in the apparatus shall be adapted to the ambient
temperature (depressurised and temperature of approx. 20°C). Only then the bolts shall be
steadily retightened with the tightening torques indicated on the drawing. The retightening of
the bolts shall be carried out cross wise and clockwise progressing over the whole circumfer-
ence. In no case must be retightened only the bolts in the direct proximity of the leakages. A
pressurization is admissible only when all screws are integrated and tightened. If leak-
tightness is not achieved, the sealing shall be replaced. The shutdown shall be effected ac-
cording to point 5.1.
zu Schadenersatz.
l) The first start-up of coolers made of copper-nickel-zinc alloys shall be effected with clean
water over a period of at least three weeks. The pH value shall be between 7.5 and 8.5.
The flow velocity of the cooling water within the tubes shall be within the range of 1.5 m/s
up to 2.5 m/s. A continuous operation with a flow velocity as constant as possible shall be
ensured.
Stoppages shall be avoided, just as the drying-out of the inner tube surfaces.
The development of biological activities within the cooling water – especially within the
tubes – must be prevented, in the case that a formation of biofilms on the tube surface is
caused by these activities. Generally, the compliance with the above mentioned flow veloci-
ties prevents the formation of biofilms.
In individual cases the use of biocides may be necessary.
Hydrogen sulphide and sulphides shall be kept away from the cooling water.

4.3 Operation
a) The tube bundle heat exchanger is designed for the operating conditions submitted to the
manufacturer. In the case of deviations the manufacturer shall be consulted.
b) The venting state in pressure chambers with fluid media shall be checked regularly. As the
case may be repeated venting shall be carried out.
c) The product feeding shall be regulated in such a manner that a sudden temperature and
pressure change can be prevented. 5 K per minute shall be considered as the maximum
guiding value for the rate of temperature change. The heating-up of the tube bundle heat-
exchanger shall be effected in a manner that no inadmissible thermal stress may occur.
d) The pressure increase permissible per time unit when there is pressure stress shall not exceed
0.5 bar per minute, in compliance with point 4.3 c).
e) The minimum and maximum values (e. g. pressures, temperatures, throughputs) indicated in
the data sheet (see point 3) shall not be exceeded.
During the operation of heat exchangers with fixed tube bundle, it must be ensured that no
inadmissible temperature differences may occur between the stated average shell wall
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temperatures and the stated average tube wall temperatures that were at the basis of the
thermal engineering calculations of the apparatus.
f) The retightening of the flange connections shall be repeated regularly in accordance with
point 4.2 c).
g) If there are leakages at the flange connections the tube bundle heat exchanger must be shut
the bolts shall be carried out cross wise and clockwise progressing over the whole
circumference. In no case must be retightened only the bolts in the direct proximity of the
leakages. A pressurization is admissible only when all screws are integrated and tightened. If
leak-tightness is not achieved, the sealing shall be replaced. The shutdown shall be effected
according to point 5.1.
h) In accordance with the operator instructions overhaul periods shall be determined. In this
context corrosion and contamination of the tube bundle heat exchanger shall be inspected.
i) An efficiency drop (deterioration of the heat transfer, increase in pressure loss) points to an
increasing contamination of the flow paths. For this reason a duly cleaning is necessary. The
complete blockage of the tube bundle heat exchanger must absolutely be prevented, because
it would not only make cleaning significantly more difficult, but would also cause a direct
danger for the tube bundle heat exchanger. Contaminations may cause different thermal
expansion of individual tubes which may result in inadmissible thermal stresses with
subsequent tube damages.
j) The tube bundle heat exchanger is always operated as part of a complete plant and not
independently. Remarks and requirements related to the operation as well as faulty usage or
faulty operation by the personnel should be indicated within the overall operation manual of
the plant.

4.4 Troubleshooting
a) Critical malfunctions/mistakes made by the personnel:

- Operation of the apparatus by untrained personnel or personnel which does not meet the
provision according to point 1.2.2
- Non-compliance with the installation instructions (point 2), the start-up measures (point 4)
and the repair work/maintenance instructions (point 5)
- Tightening of the screwing of both of the saddle bearings (heat-related expansion of the
gas cooler must be ensured)
- Faulty connection of the apparatus to the tube lines
- Operation of the apparatus beyond the given technical data (see point 3)
b) Actions to be taken in the case of malfunction/disaster:

- In all cases of malfunction the shutdown (according to point 5.1) of the apparatus, a
troubleshooting and a fault correction become necessary, e. g.:
1) in the case of a pressure increase beyond the maximum value stated in point 3
with no pressure reduction possible to carry out by the operator
2) upon failure of a safety valve
zu Schadenersatz.
3) upon signs of fatigue of the material of the main components (e. g. cracks, dents,
failure of the sealing, leaky welding seams)
4) upon erroneous function of measuring instruments
- Maintenance and repair works on a pressurized apparatus are not allowed
- Leakage on connections/flange connections because of:
1) defect seals, flange, flange sealing surface, flange connection
2) fatigue of material
3) inadmissible tensions/forces
 check/tighten flange connection

 check tube line system for undesirable tensions/forces
 check/clean replace seals
 observance of point 5
- Increased loss of power because of:
1) Failure in the complete plant
2) Quality of the medium
3) Foreign objects/accumulations in the tube lines

 inspection of the complete plant + correction of faults
 inspection of the quality of the medium + maybe clean/ filter/replace the
medium
 opening and cleaning of the apparatus (according to point 5.3)

5 Repair Work and Maintenance Instructions
5.1 Shutdown
a) Tube bundle heat exchanger with fixed bundle and respectively with stuffing box:
When shutting down, the shell side is to be shut down after the tube side.
Tube bundle heat exchangers with floating head and U tube bundle:
First, shut down the warmer medium, irrespective of shell side or tube side.
b) The tube bundle heat exchanger shall be depressurized; it must be in a pressure-less state.
The internal temperature shall be lowered to a temperature at which no danger may arise.
The tube bundle heat exchanger must be reliably disconnected from all systems (e. g. set
blanking plates) and if necessary it must be damped and rendered inert.
c) Via the drain openings (see drawings) the medium shall be removed completely from the
tube bundle heat exchanger. To this end, the venting hole (per room) at the highest point
must be opened in order to prevent the creation of underpressure within the tube bundle heat
exchanger when the medium runs off. In the case of products dangerous to health and
explosive products the container must be rinsed in accordance with the legal requirements.
zu Schadenersatz.
Only then the bolts of the flange connections may be untightened.

d) The complete draining should also be carried out when the tube bundle heat exchanger shall
be shut down, but not opened, for a longer period of time. This prevents for example the risk
of corrosion and/or damage due to frost.
e) In the case of a longer shutdown it is advisable to preserve the machine by means of a
nitrogen filling (at an overpressure of 0.5 bar(g)) and to mark it in an appropriate manner.
But prior to that, the tube bundle heat exchanger must be completely drained and dried. The
drying may be carried out by means of evacuation or sparging with dry air. This action needs
to be pursued until the relative air humidity at the outlet-side is 30% related to 20 °C. The
check for the residual moisture in the apparatus may be carried out by means of a dew point
measurement (minus 10 °C). If there is no cooling water recirculation the cooler must be
completely drained, dried and preserved in an appropriate way. There is also the possibility
of a chemical stoppage preservation.
5.2 Disassembly
a) Prior to any disassembly it shall be checked if all spare parts such as spare seals are
available. Spare seals shall be ordered from the manufacturer in due time.
b) The slinging for the disassembly shall be carried out at the attachments points and the sling-
ing scheme provided for this purpose. The stated maximum load capacity of the supporting
elements must not be exceeded. The required indications are stated in the drawing. When us-
ing carrying devices such as belt straps the corresponding safety regulations and guidelines
of the country in which the apparatus is installed shall be observed. During the disassembly
care shall be taken to ensure that no damage of nozzles, nozzle sealing surfaces or other at-
tachment parts occurs.

c) In the case of tube bundle heat exchangers that are arranged one upon the other (block or
battery construction) the pulling of the tube bundle of the upper tube bundle heat exchanger
may take place only after the disassembly of the block/battery und after the mounting of the
single tube bundle heat exchanger on an appropriate working surface.
d) The pulling of removable tube bundles shall be carried out in compliance with the safety
provisions. Prior to the pulling of the tube bundle, the following steps must be performed and
controlled:
1. Shell side drained and depressurized.

2. Loosen and remove all connections which are opposed to the tube pulling.
3. If existent, the intermediate ring/the stuffing box and their corresponding seals shall be
loosened and disassembled.
e) In order to avoid damages the bundle shall be lifted only at the points provided for that
purpose (e. g. lifting hooks) and by means of suitable auxiliary means (load bearing layers)
as well as without any diagonal pull. For taking up the tube bundle that had been pulled out
suitable supports shall be provided in order to prevent the bending of installed equipment (e.
g. transverse baffles and supporting plates, support grids and brackets).
zu Schadenersatz.
f) The transmission of the pulling and pushing forces for the pulling and the insertion of the
bundle shall be carried out with the utmost caution at the devices provided for that purpose
(drawbar eyes or cleats).
g) When dealing with tube bundle heat exchangers with internal coating the damage of the
coating shall be prevented. Destroyed coatings shall be removed immediately in accordance
with the provision of coating manufacturer.
h) Inlet and outlet chambers and covers are removed from the housing (by using the forcing
screw if available) and they shall be placed on a suitable surface.
5.3 Cleaning
a) Prior to the cleaning of the tube bundle heat exchangers they shall be depressurized, drained,
reliably disconnected from all systems (e. g. set blanking plates) and if necessary be damped
and rendered inert. Observe point 4.1.
b) For the cleaning of the tube bundle heat exchangers the use of substances/media that damage
the material is not allowed. Mordants are inadmissible.
c) When cleaning the tube bundle heat exchangers the applicable safety provisions for the use
of the cleaning materials shall be observed.
d) Attention! All sealing surfaces shall be perfectly cleaned.
e) The cleaning of tube bundle heat exchangers with fixed bundle by means of damping is only
admissible if this operation mode has been notified to the manufacturer of the apparatus
within the order. Otherwise, the manufacturer shall be consulted in writing prior to this
procedure.

f) The connecting tube lines to the draining and venting nozzles as well as these nozzles and the
nozzles with blind flange shall be cleaned. Afterwards the nozzles shall be reclosed and the
connecting tube lines shall be reinstalled.

g) When dealing with tube bundle heat exchangers with internal coating the indications of the
coating manufacturer shall be observed (see annexe if available).
h) If the tube bundle is connected to the shell/chamber by additional screws, collar screws or
other auxiliary equipment, the operator must ensure the pressure-less state of both pressure
chambers.
A cleaning by rinsing shall takes place under pressure. This is only admissible when all
screws are integrated and tightened.
i) Chlorides reduce the corrosion resistance of chrome-nickel steels and of chrome-nickel-
molybdenum steels (also Hastelloy, Incoloy, Inconel)! The effect of the chlorides depends on
concentration, temperature and pH value of the medium.
5.4 Maintenance
a) In accordance with the legal provisions for pressure equipment and the competent
surveillance authority overhaul periods shall be determined. In this context shall be checked
zu Schadenersatz.
for instance the leak tightness, the corrosion damage and, in the case of efficiency drop, the
contamination within the tube bundle heat exchanger.
b) The tube bundle heat exchangers are generally maintenance-free. However, we recommend
to the operator to regularly check the flange connections for leak tightness. In the case of
aggressive and dangerous media as well as when there are frequent load changes the time
intervals should be reduced after the first start-up, after the re-start after longer stoppage and
after instable system conditions.
j) Maintenance and repair works are not permitted on a pressurized tube bundle heat exchanger.

5.5 Options of Repair

a) Defect seals:
At the opened flange connections the sealing surfaces shall be cleaned and possible damages
shall be eliminated before the installation of new seals is carried out. The installation of seals
must be carried out with the utmost care. After the renewal of the seals, the flange
connections shall be equipped with the number of bolts indicated on the drawing and shall be
tightened according to the bolt tightening torques (see drawing) cross wise and clockwise
progressing over the whole circumference. The thread of the bolts and nuts shall be treated
with an appropriate lubricant (see drawing).
b) Leaky inner tubes:
Should a heat exchange tube become leaky because of unexpected influences, the repair
technology shall be agreed with the manufacturer prior to such a repair or another repair (e.
g. replacement of inner tubes).
zu Schadenersatz.
5.6 Reassembly / Pressure Test
a) The transport of the parts of tube bundle heat exchangers takes place by means of the
intended supporting elements.
b) The insertion of bundles into tube bundle heat exchangers of block/battery construction must
only be carried out as single tube bundle heat exchanger on a suitable working surface,
unless another technical solution has been agreed.
c) The transmission of the pulling and pushing forces for the insertion of the bundle shall be
carried out with the utmost caution at the devices provided for that purpose (drawbar eyes or
cleats).
d) For the fastening and the horizontal mounting of the chambers 3 bolts for each with one nut
(from the flange connection fasteners) shall be arranged at equal distances at the housing
flange. The threads of the bolts and nuts shall be treated with an appropriate lubricant.
e) Prior to the reinstallation and after having cleaned the sealing surfaces and eliminated
possible damages the flange connections shall be equipped with new seals. The replacement
of the seals shall be carried out with the utmost care.
f) The threads of the bolts and nuts shall be treated with an appropriate lubricant. All apparatus
flange screw connections shall be tightened steadily cross wise and clockwise progressing
over the whole circumference. The tightening takes place in 3 steps. Lubricants and
tightening torques see drawing.
g) After the installation has been effected the tube bundle heat exchangers shall be tested in a
pressure test. This pressure test is performed as indicated in the drawings.
- In the case of the pressure test with water the pressure chambers shall be vented
completely. The pressure test shall be recorded; see point 6.3. The quality of the test
medium shall comply with the respective operator specifications. If the test water
quality is not specified by the operator, for the tube bundle heat exchangers made of

stainless steel a maximum chloride content of ≤ 20ppm shall apply and for C-steel
apparatus no restrictions are necessary in relation to the water quality.
-
For the pressure test with gas the respective applicable safety provisions are to be
observed.
h) After the end of the pressure test with water and no immediate restart, the equipment must be
dried by means of evacuation our sparging with dry air. This action needs to be pursued until
the relative air humidity at the outlet-side is 30% related to 20 °C. The check for the residual
moisture in the apparatus may be carried out by means of a dew point measurement (minus
10 °C).
i) During the start-up and the performance of pressure tests the pressures and temperatures
indicated on the factory nameplate and on the drawings shall be observed and not be
exceeded.
j) In the case of pressure tests with water carried out at a temperature below 0 °C it must be
ensured that the water in the apparatus and in the measuring instruments does not freeze.
Point f) shall be observed.
5.7 Restart
zu Schadenersatz.
see chapter 4.2
5.8 Operation
see chapter 4.3

5.9 Spare and Wear Parts
If spare and wear parts are included in the delivery they will be supplied in a separate package or
in the package of the main equipment. If spare and wear parts are not included in the delivery
they may be ordered from the manufacturer as needed. Care shall be taken to ensure that during
the transport, storage and installation no damage may occur due to external influences (see also
point 2.4).

The copying, distribution and utilization of this document as well as the communi- Weitergabe sowie Vervielfältigung dieses Dokuments, Verwertung und Mitteilung seines
cation of its contents to others without expressed authorization is prohibited. Of- Inhalts sind verboten, soweit nicht ausdrücklich gestattet. Zuwiderhandlungen verpflichten
fenders will be held liable for the payment of damages. zu Schadenersatz.
E-mail:
Telefax:
Internet:
Address:
5.10 Service AEL
Germany
www.ael.de
[email protected]
Telephone: +49 34321 61-0
D-04703 Leisnig
Döbelner Straße 9
+49 34321 61-118
AEL Apparatebau GmbH Leisnig

General Operation and Maintenance Manual
Rev. 0
Page 23 / 24
6 Annexes
6.1 Annexe 1: Forms for the Recording Repeated Pressure Test
Denomination: Gland Steam Condenser

Project: TIMOR 1
Customers order No.: B220-18214-3511
AEL job No.: 3120002
AEL drawing No.: 65-2432X
Ident No.: 1203.100601
shell side tube side shell side tube side

test pressure (bar Ü)
temperature test medium (°C)
test medium
quality of the test medium

zu Schadenersatz.
according to point 5.1 has been

observed
manometer No. with calibration

certificate
record of the pressure recorder

pressure test performed by:
results of the pressure test

date
stamp & signature

7. Radial Ventilator
7. radial fan

Commission-N°:
7001021687
Factory-N°:
4020004 Project:
TIMOR 1
Drawing-N°:
BB2285A
Baujahr: Pos.-Nr.:
Komponente: Ventilatoren 11MAM65AN110

component: Fans 11MAM65AN120
Einbauerklärung unvollständige Maschine

1.
Declaration of incorporation of partly completed machinery
Datenblatt Drehstrom-Käfigläufermotoren 1CV3083A
2.
Data sheet for three-phase Squirrel-Cage-Motors 1CV3083A
Montageanleitung
3.
Intsallation instruction
Ersatzteilliste
4.
spare part list
Karl Klein Ventilatorenbau GmbH
Waldstrasse 24
D-73773 Aichwald

According to Directive 2006/42/EC, Annex II part 1 B
This is to declare that the products:

Radial fans, Types: EEG... / DEG... / ENG... / DNG... / EMV... / DMV ... / EMVL.../
DMVL ... / ESV… / DSV… / EHV… / DHV…, all from year of manufacture 2010 on,
NHV... / MHV... / HHV... / MVG... / TVG... / HF... / PF..., all from year of manufacture 2012 on,
FLN... from year of manufature 2019 on
as far as possible regarding our scope of delivery, generally comply with the directives as follows:
Council Directive 2006/42/EC (Machine Directive)
Furthermore effectual directives:
The safety objectives of the low voltage directive (2014/35/EC), accordingly annex I, No. 1.5.1 of the machine
directive 2006/42/EC are fulfilled.
Note: For ATEX- types only exists a separate EC-Declaration of Conformity according ATEX Directive.
Note: There are separate declarations of conformity of the manufacturers for the electrical components.
Following harmonized standards were applied:

EN ISO 12100:2010
EN 15085-2…-5:2007 Railway applications - Welding of railway vehicles and components – Certification degree CL2.
Information: EN 15085 part 2 to 5:2007 ist maintained if it is aggreed with an order only.
We furthermore declare, that the special technical documents for partly completed machinery were prepared
according appendix VII part B and we commit to deliver these documents on demand to the commercial supervisory
authorities.
Note: Initial operation of the incomplete machinery is prohibited as long as it is not installed into a
complete machine which complies with the Council Directive 2006/42/EC and as long as the
appropriate Declaration of Conformity according annex II A is not on hand.
The authorized person for the compilation of the technical documents is the subscriber.
City / date Signature and functioning of subscriber
Aichwald, july, 12th 2019 Siegfried Seidler, Technical Manager
Annex
Followed Requirements of the annex I of 2006/42/EC. The figures are refering to paragraphs of
annex I: 1.1.2, 1.1.3, 1.3.4, 1.7.4.2 (partly)
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ORIGINAL INSTALLATION INSTRUCTION
Installation instruction GB
for Page 1
Radial Cast Iron Fan
Version 07/2019
Apoguss
Manufacturer: Karl Klein

Ventilatorenbau GmbH
Waldstr.24 D-73773 Aichwald
Tel.: +49-711-369060 Fax: +49-711-36906950

E-mail: [email protected] http: //www.karl-klein.de
Fan type: MVG

designed for transported material temperatures
up to 200°C
TVG for conveying particles in gaseous

media
up to 120°C
Karl Klein Ventillatorenbau GmbH  Waldstr. 24  D-73773 Aichwald (Germany)

Tel.: +49 71136906-0  Fax: +49 71136906-950  E-mail: [email protected]  http: //www.karl-klein.de
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MVGR with belt drive

up to 200°C

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MVGK with coupling drive

up to 350°C

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General conditions for the use of Karl Klein fans

These general conditions set out the basic rules for the proper use of the fans. Where necessary
they are supplemented by the information and specifications provided in the Installation
instruction. The individual conditions are as follows:
 All maintenance instructions must be observed.

 All safety devices must be correctly installed.
 Changes to factory settings are not permitted without our approval.
 Only lubricants specified by the factory, or equivalent, may be used. Contamination is not permitted.
 If the machines are installed in a fixed position, the foundations must be expertly produced in accordance with DIN 4024, Part
2, and the machine secured in accordance with our recommendations.
 Reactive forces associated with connection of pipe lines must be restricted to a minimum, for example by using compensators.
Where maximum loads for nozzles are specified in the dimension sheet, these must never be exceeded.
 No liability will be accepted for faults caused by inexpert placing into operation by the customer.
 Exceeding the maximum temperatures and speeds given in the specifications is not permitted even briefly.
 Foreign bodies are not permitted to enter the impeller.
 Only the substances (gas compositions) specified in the order are permitted to be conveyed. Any damages caused by non-
specified media compositions are excluded from the warranty agreement.
 The fans may only be operated in a smooth-running condition. The permissible levels of bearing vibration are defined by the
alarm and shut-down values specified in the Installation instruction.
 The alarm and shut-down functions on fans with vibration monitors must be in accordance with the limits specified in the
Installation instruction. Operation above the alarm value is only permitted on a temporary basis for analysing the cause of
vibrations. If the vibration values suddenly change for the worse, this may be a sign that the machine or part of the machine
is at imminent risk of failure, jeopardising operational safety in the process. The causes have to be determined immediately
and remedial action taken accordingly.
 Operation of the fans without vibration monitors is only permissible if the vibration levels do not exceed the limit values given
in the Installation instruction (if no information is provided, 7.1 mm/s for fixed installation according to ISO 14694 BV-3; 4.5
mm/s for fixed installation according to ISO 14694 BV-4).
 Modifications to the impellers in connection with operational balancing of the customer have to be agreed with us. Any
unauthorised measures shall render the warranty void.
 System-related swirling of the gas flow in the direction of rotation of the impeller must be prevented; counter-swirling is not
permitted.
 Continuous operation is only permitted for the operating points specified in the order confirmation; in particular, operation with
a closed slide valve or closed flow restrictor is only permitted for a short time (max. 5 minutes for start-up assistance).
 For fans with vane controllers, all fan controller positions require approval for operation, with the exception of a closed vane
controller (90° or 0%). Operation with a closed vane controller is only permissible during start-up. The vane controller must be
opened quickly as soon as the final speed has been reached. For applications with pressure increases in excess of 10kPa,
the permissible vane controller positions in continuous operation must be restricted to a maximum of 70°.
 It is essential that the flow rate never falls below a minimum flow rate Vmin = 0.3 * Vopt in continuous operation; for pressure
increases greater than 20 kPa the minimum flow rate has to be raised to 0.5 * V opt and operating points with pressure increases
of less than 40% of the pressure increase in the design point have to be blocked.
 In the case of free intake, the inflow to the fan must be unimpeded. The minimum dimensions of the unimpeded rectangular
space around the centre-point of the intake opening is a = b = 2.5 * d (d = intake diameter).
 Heavy caking, corrosion and visible wear on impellers are inadmissible. Prevention measures must be agreed with us
immediately.
 The surge-like entry of liquids into the impeller and inadequate removal of condensation from the fan housing must be
prevented under all circumstances.
 If the motor is provided by the customer, we do not provide a warranty for design and function or for the operational safety of
the coupling drive/belt drive in the event of electrical malfunctions (according to VDI 3840).
 The fans may only be started up when the machine is at a standstill.
 Where process temperatures are over 140°C, the fan is not permitted to be at a standstill because this may lead to damage
to the bearings.
 Temperature gradients of more than 50°C/min are inadmissible, unless agreed otherwise.
 If fans are operated in parallel, operation to the left of the peak of the characteristic curve must be blocked.

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Transfer of PILLER housing positions to Karl-Klein housing positions
PILLER (Eurovent): KARL KLEIN:

Clockwise (facing motor) Anti-clockwise (facing intake)
L0 L315 L270 L225 L180 L90 L45

Anti-clockwise (facing motor) Clockwise (facing intake)
R0 R315 R270 R225 R180 R90 R45

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Table of contents
1 GENERAL INFORMATION............................................................. 9
1.1 General description ....................................................................................... 9
1.2 Intended use .................................................................................................... 9
1.3 Declaration of incorporation of partly completed machinery ...................... 9
2 SAFETY INFORMATION .............................................................. 11
2.1 Symbols ......................................................................................................... 11
3 LIMIT VALUES ............................................................................. 14
4 NOTES AND INSTRUCTIONS ON SAFETY ................................ 14
4.1 Basic safety information............................................................................... 14
4.2 General notes and instructions on safety ................................................... 14
5 SPECIALISTS ............................................................................... 16
6 ELECTRICAL CONNECTION CONDITIONS ............................... 16
7 WARNINGS, LABELS .................................................................. 16
8 RESIDUAL RISKS ........................................................................ 17
8.1 Overview of hazards ..................................................................................... 17
9 DESCRIPTION OF THE PRODUCT ............................................. 19
9.1 Motor .............................................................................................................. 19
9.2 Housing ......................................................................................................... 21
9.3 Impeller .......................................................................................................... 21
9.4 Seal at the shaft exit ..................................................................................... 21
9.4.1 MVGR fans ..................................................................................................... 21
9.4.1.1 Belt drive ................................................................................................... 21
9.4.2 MVGK fans ..................................................................................................... 21
9.4.2.1 Coupling .................................................................................................... 22
9.4.2.2 Cooling impeller ........................................................................................ 22
10 ITEMS SUPPLIED AND TEMPORARY STORAGE ...................... 23
11 INFORMATION ON TRANSPORTATION..................................... 23
11.1 Safety information for transportation .......................................................... 23
11.2 Transport instructions .................................................................................. 23
11.2.1 MVGK fans ..................................................................................................... 24
12 INSTALLATION ............................................................................ 26
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13 PLACING INTO OPERATION / TEST RUN .................................. 27

14 SWITCHING ON THE FAN ........................................................... 28
15 SWITCHING OFF THE FAN ......................................................... 28
16 SERVICING AND MAINTENANCE ............................................... 29
16.1 MVG fans ....................................................................................................... 30
16.1.1 Motor............................................................................................................... 30
16.1.2 Housing........................................................................................................... 30
16.1.3 Impeller ........................................................................................................... 31
16.1.4 Shaft seal ........................................................................................................ 31
16.1.5 Tightening torque ............................................................................................ 31
16.1.6 Checking the screw connections ..................................................................... 31
16.1.7 Checking for leaks........................................................................................... 31
16.1.8 Storage and corrosion protection instructions.................................................. 32
16.1.9 Removal of protection against corrosion ......................................................... 32
16.2 MVGR fans ..................................................................................................... 33
16.2.1 Motor............................................................................................................... 33
16.2.2 Housing........................................................................................................... 33
16.2.3 Impeller ........................................................................................................... 33
16.2.4 Shaft seal ........................................................................................................ 33
16.2.5 Bearing ........................................................................................................... 33
16.2.6 Belt drive ......................................................................................................... 33
16.2.10 Storage and corrosion protection instructions ............................................. 35
16.2.11 Removal of protection against corrosion ..................................................... 35
16.3 MVGK fans ..................................................................................................... 36
16.3.1 Motor............................................................................................................... 36
16.3.2 Housing........................................................................................................... 36
16.3.3 Impeller ........................................................................................................... 36
16.3.4 Bearing ........................................................................................................... 36
16.3.5 Shaft seal ........................................................................................................ 36
16.3.6 Coupling drive ................................................................................................. 37
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16.3.11 Tightening torque ........................................................................................ 38
16.4 MVGK fans ..................................................................................................... 41
16.5 MVGR fans ..................................................................................................... 41
17 DISASSEMBLY ............................................................................ 43
18 DISPOSAL .................................................................................... 43
19 SPARE PARTS ............................................................................. 44
20 DECLARATION OF INCORPORATION OF PARTLY
COMPLETED MACHINERY ......................................................... 49

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1 General Information
1.1 General description

The partly completed machine described in this Installation instruction is a cast radial fan.
The term radial fan refers to machines use to convey air, air-like gases or gas mixtures. Radial fans operate on the basis
of centrifugal force. The air therefore flows into the fan parallel to the axis of rotation, but is then deflected at right-angles
before it enters the impeller and is thrown out to the outside by centrifugal force. The term radial fan is derived from the
fact that the medium moves on a radius of the impeller after it has been deflected.
The fan is normally comprised of the following components:
- Housing with openings on the intake and pressure sides
- Impeller in a housing, mounted on a shaft
- Stand, which supports the housing, bearing unit and drive unit (motor)
- As a general rule, pipe lines supplied by the customer and fitted to the openings on the intake and pressure
sides
A fan in the case of the present application is a flow machine which is subjected to high dynamic loads
and may only be operated by qualified personnel!
1.2 Intended use

The fan is designed exclusively for conveying the medium specified in the data sheet/order documents for the machine,
and subject to the operational parameters specified therein. Any use beyond the aforementioned use and any deviation
from the operational parameters which exceeds the general safety instructions, shall be regarded as improper use. The
manufacturer shall not be liable for any damages resulting from such improper use. In this case the risk is borne solely
by the user.
The definition of intended use also encompasses observing the operating, maintenance and servicing conditions
specified by the manufacturer.
The fan may only be operated, serviced and repaired by persons who are familiar with it and have been informed about
its potential hazards.
The applicable accident prevention regulations and all other generally recognised rules relating to health and safety at
work and road traffic must be complied with.
The manufacturer will not be liable for any damages resulting from unauthorised modifications to the machine.
1.3 Declaration of incorporation of partly completed machinery

The fan described in this Installation instruction conforms with the safety and health requirements of European Machinery
Directive 2006/42/EC. If properly installed and maintained and used in accordance with the intended use it will not
compromise the health or safety of persons or the safety of property.

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It is essential that you read the "Safety instructions" chapter in this Installation instruction
before placing the fan into operation.
Before placing the fan into operation for the first time and each time it is started up again
after inspection and maintenance work, it has to be ensured that all foreign bodies, tools,
scaffolding and auxiliary equipment have been cleared from the fan housing and
downstream ducts.
All safety equipment such as emergency stop switches, shaft protection, coupling
protection, etc., must be installed.
Cordon off the fan's danger zone to unauthorised persons over a wide area and switch on
the fan from a safe distance.
.
Persons, animals or loose objects must never be allowed to stand in the air flow or be
suctioned in!
The air flow generated by the fan can be so powerful that it is capable of sucking in or
blowing away a human body or heavy objects.
It is imperative that all supplied and agreed/provided safety devices such as temperature,
vibration and speed monitors, etc., are connected and also checked to ensure that they
are in perfect working order at all times.

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2 Safety information
2.1 Symbols
Symbols are used in this Installation instruction and on the fan which must be given special attention:
This draws attention to hazardous situations involving a risk of personal injury and damage to property.
Risk of danger from electricity. Work to be carried out may only be carried out by an electrician.
Information relating to protection of the environment
Beware of risk of injuries to hands
Beware of suspended loads
Beware of hot surfaces
Beware of rotating parts
Beware of caustic substances
Beware of fall hazard
Beware of harmful substances
Beware of potentially explosive atmosphere

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Beware of toxic substances
Slinging points for transporting the fan
Centre of gravity of the fan
Manual arc welding prohibited on the fan
No access for persons
Read this Installation instruction before placing into operation
Wear ear protection

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MANDATORY REQUIREMENT Observe instructions!

It is imperative that the specified safety instructions must be observed.
MANDATORY REQUIREMENT Wear ear protection!

Ear protection must be worn for all work on the system.
MANDATORY REQUIREMENT Wear safety footwear!

Safety footwear must be worn for all work on the system.
MANDATORY REQUIREMENT Wear gloves!

Suitable safety gloves must be worn for all work on the system.
MANDATORY REQUIREMENT Wear safety glasses!

Safety glasses must be worn for all work on the system.

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3 Limit values
Limits for which operation of the fan must be stopped:
MACHINE VIBRATIONS
Measured at the bearing points
Alarm:  7.1 mm/s (Check the fan as quickly as possible)
Shut-down:  9.0 mm/s (The fan must be switched off immediately)
MEDIUM TEMPERATURES
With Felt-ring-sealing -15 up to +120 °C
With Coal-swim-ring-sealing -15 up to +200 °C
With Coal-swim-ring-sealing and cooling radiator at 4-pole motor -15 up to +300 °C
MVGR, MVGK
BEARING TEMPERATURES
Alarm  90°C (The fan can continue to be operated)
Shut-down  100°C (The fan must be switched off immediately)
4 Notes and instructions on safety
4.1 Basic safety information

The fan has been constructed in accordance with the latest state-of-the-art in technology and approved technical rules
concerned with safety. Nevertheless, it may still be a source of danger to the life and limb of the operator or other persons
during operation, or of impairment to the machine and other items of property.
The fan must only ever be used in perfect technical condition, in accordance with the intended use and with proper regard
for safety and dangers and the instructions in the Installation instruction. In particular, any faults which compromise safety
must be eliminated immediately.
4.2 General notes and instructions on safety

4.2.1 In addition to observing the notes and instructions contained in this Installation instruction, you must also observe the
general regulations concerned with safety and the prevention of accidents.
4.2.2 The owner-user is responsible for ensuring that the machine is only used when it is in perfect working order.
4.2.3 Changes to factory settings are not permitted without our approval!
4.2.4 The fans may only be started up when the machine is at a standstill.
4.2.5 Exceeding the maximum temperatures and speeds given in the data sheet is not permitted even briefly!
4.2.6 Before connecting up the electrical connections of the motor, the manufacturer's instructions relating to safety and
commissioning and the requirements of DIN VDE 0105 or IEC 364 must be taken into account!
4.2.7 Modifications to the impellers in connection with operational balancing of the customer have to be agreed with us.
4.2.8 It must be ensured that fluids or dissimilar materials are prevented from getting into the fan to the extent that they can be
conveyed by the impeller! If any fluids are conveyed, this will damage the impeller beyond repair! Provision must be
made to ensure that condensate is effectively removed from the fan housing!
4.2.9 Caking, corrosion and visible wear on impellers are inadmissible! Prevention measures must be agreed with us
immediately!
4.2.10 System-related swirling of the gas flow in the direction of rotation of the impeller must be prevented; counter-swirling is
not permitted!
4.2.11 It is essential that the flow rate never falls below a minimum flow rate Vmin = 0.3 * Vopt in continuous operation; for pressure
increases greater than 20 kPa the minimum flow rate has to be raised to 0.5 * V opt and operating points with pressure
increases of less than 40% of the pressure increase in the design point have to be blocked! The impeller will be damaged
beyond repair if the fan is operated for longer periods at below specified flow rates! Short operating states (start-up and
shut-down) of less than 5 minutes duration per day are permissible!

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4.2.12 The cleaning opening on the fan housing may only be opened when the machine is at a standstill! The fan must be
secured to prevent it starting up again during this time!
4.2.13 The fans may only be operated in a smooth-running condition. The permissible levels of bearing vibration are defined by
the specified alarm and shut-down values if vibration monitors are provided.
4.2.14 The alarm and shut-down functions must be in accordance with the limits specified in the Installation instruction.
Operation above the alarm value is only permitted on a temporary basis for analysing the cause of vibrations! If the
vibration values suddenly change for the worse, this may be a sign that the machine or part of the machine is at imminent
risk of failure, jeopardising operational safety in the process! The causes have to be determined immediately and remedial
action taken accordingly!
4.2.15 Operation of the fans without vibration monitors installed is only permissible if the vibration levels in the bearing planes
do not exceed a maximum value of 9.0 mm/s (ISO 14694 BV-3)! For an optimum machine service life, the maximum
vibration levels should be restricted to 7.1 mm/s! Process-relevant fans need to have their vibration levels checked and
documented at regular intervals (every 14 days as a minimum).
4.2.16 Fan components which may be touched accidentally during normal fan operation; drive or supply systems with an
external surface temperature of over 65°C or below minus 12.5°C must be protected, insulated or provided with warnings
(see DIN EN 563).
4.2.17 Electrical and mechanical safety equipment provided by the customer must comply with the requirements of DIN EN
60204-1, DIN EN ISO 13857 and DIN EN 349.
4.2.18 The build up of electric charges must be prevented by the earthing of components. In this regard, compliance with DIN
EN 50081 Parts 1 and 2 is required.
4.2.19 The pipe lines and the housing must be inspected at regular intervals to check for the presence of foreign bodies. These
must not be permitted to get into the inside of the fan.
4.2.20 The fan may only be operated with pipe lines connected or the use of mesh guards. Mesh guards in front of the intake
opening for free intake must not be capable of being removed using tools.
4.2.21 The fan must be examined for transport damage before it is placed into operation and must not be placed into operation
if there is any damage.
4.2.22 The machine may only be operated if guards are installed, using the original means of fastening.
4.2.23 Welding work on the fan is prohibited and will unavoidably render the warranty void.
4.2.24 If buffer gases are used on shaft exits, they must not be harmful. They must be compatible with the medium and must
not corrode, modify or break down any of the existing materials.
4.2.25 Controllers for speed-controlled drives have to be set so that there is no possibility of resonance with the resonant
frequencies of the mechanical system.
4.2.26 Guide mandrels must be used for installation and maintenance work.
4.2.27 Appropriate precautions must be taken against falling when carrying out maintenance and repair work.
4.2.28 Operation on a 60Hz mains system is not permitted for 50Hz machines.
4.2.29 To prevent electric shocks caused by contact with live parts, connect metal cable ducts and cable sheaths to the
protective conductor system.
4.2.30 The incoming feeder must be switched off automatically by overcurrent and earth-leakage circuit-breakers.
4.2.31 Incorrect displays and malfunctions on the monitoring and control systems caused by interference from electromagnetic
fields in the signal cable or power supply cables must be prevented by sufficient shielding, including in the control
cabinets.
4.2.32 It is imperative that ear protection be worn for noise emissions of 85 dB(A) and over.
4.2.33 The customer must provide adequate illumination for the work area for all maintenance and servicing work.
4.2.34 If operated on a frequency converter, the maximum speed must be locked.
4.2.35 An automatic restart after the power supply has been restored is inadmissible and must be prevented.
4.2.36 The customer must provide and use lockable central switches and install emergency stop switches.
4.2.37 Lubrication of the bearings must be ensured by strict observance of lubrication regulations and regular maintenance,
including checking the bearing temperatures.
4.2.38 Maintenance must be carried out at regular intervals in accordance with our Installation instruction!

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5 Specialists
The work of placing into operation may only be carried out by specialists who, on the basis of their professional training,
experience and instruction, have sufficient knowledge of:
- Directives, guidelines and generally recognised codes of practice -

- Safety regulations
- Accident prevention regulations
The specialists must:
- be assigned/contracted to do the work by the company;

- be capable of assessing the work they have been assigned/contracted to do;
- be capable of recognising and preventing or avoiding potential hazards;
- be authorised to undertake the necessary work and activities by the individual responsible for safety.
Only deploy reliable and trained personnel who have been familiarised with the work. Only qualified electricians
(according to the definition of specialists in DIN VDE 0105 and IEC 364) are permitted to carry out any work or checks
on electrical components!
This must be in compliance with the valid, applicable:
- national regulations;
- safety regulations;
- accident prevention regulations.
The applicable regulations (VDE, etc.) relating to the handling of electrical equipment, e.g.
- disconnection;
- securing to prevent equipment being switched on again;
- verifying that equipment is disconnected from the power supply;
- earthing and short-circuiting;
- covering or safeguarding of adjacent live components,
must be complied with.
Electricians are defined as persons who, on the basis of their professional training, experience and instruction, have
knowledge of the applicable standards, regulations and accident prevention regulations. They must also be capable of
assessing the work they have been assigned to do and recognising potential hazards.
6 Electrical connection conditions

For the connection of the electrical components, the valid, applicable national standards apply. In this connection it is
important to ensure that the regulations of the relevant power supply companies are also taken into account.
Only qualified electricians (according to the definition of specialists in DIN VDE 0105 and IEC 364) are
permitted to carry out any work or checks on electrical components!
7 Warnings, labels
All information signs affixed to the fan (such as slinging points, centre of gravity positions, direction of rotation arrows,
plus possible information relating to lubrication and belt drives) must be observed and kept in a legible condition.

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8 Residual risks
The residual risks listed below still remain in spite of the measures taken with regard to the integration of safety in the
design, and in spite of the safety precautions and the supplementary safety measures taken, and must therefore be given
special attention.
8.1 Overview of hazards
Type of hazard Danger Danger area Action

Crush injuries/damage due to Fatal injury, damage to Installation and Observe transport
falling parts / machines property assembly instructions
Shearing when installing Risk of injury Installation and Observe the Installation
machine components assembly instruction; use guide
mandrels
Drawing into the fan housing Fatal injury Intake opening Observe the Installation
instruction; observe
safety distances
Parts of the body and clothing Risk of injury, damage to All rotating parts Observe the Installation
getting drawn into the drive property instruction; do not
elements remove safety
equipment
Loss of stability Risk of injury, damage to Transportation and Observe the Installation
property operation instruction;
observe transport
instructions;
proper transportation;
proper foundations and
fastening
Slipping, falling Risk of injury Installation and Observe the Installation
assembly and instruction;
maintenance take appropriate
measures against falling
and crashing
Electric shock Fatal injury Direct danger from Observe the Installation
contact with live parts; instruction;
indirect danger from observe safety
faulty live parts regulations
Electric shock caused by Fatal injury Contact during Observe the Installation
electrostatic discharge operation instruction;
observe safety
regulations;
earth the housings
Burn or freezing injuries due to Risk of injury; Hot/cold machine Observe the Installation
hot/cold machine components Risk of explosion due to components instruction;
increased risk of ignition marking;
wear safety equipment
Loss of hearing or physiological Risk of injury Noise levels over 70 Observe the Installation
impairment due to machine dB(A) instruction;
noise marking;

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Danger due to materials and Risk of injury, damage to Installation, assembly, Observe the Installation
other substances property maintenance and instruction;
operation Prevent foreign bodies
from entering; provide
sufficient ventilation;
marking;
Wear safety equipment
Combination of hazards Risk of injury, fatal injury, Inexpert installation Observe the Installation
damage to property, harm and placing into instruction
to the environment operation; operating
errors
Unexpected start-up Fatal injury Maintenance, repair Observe the Installation
instruction;
observe safety
regulations; lockable
central switch
Escaping high-pressure fluid - Risk of injury Maintenance and Observe the Installation
buffer fluids on shaft seals operation instruction;
observe safety
regulations; limitation of
buffer fluid connection
pressure
Inadequate monitoring Risk of injury, damage to Operation Observe the Installation
property instruction;
observe safety
regulations;
connection and
activation of monitoring
functions
Impeller breakage, parts Risk of injury, fatal injury, Fan housing, Observe the Installation
catapulting out damage to property, harm operation instruction;
to the environment observe safety
regulations; proper use

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9 Description of the product
9.1 Motor
General information
There are live parts and rotating parts on the inside of the electric motors. All connection, commissioning and maintenance
work must therefore be carried out as a general rule by qualified specialists in accordance with the information and
specifications provided by the manufacturer. The requirements of DIN VDE 0105 or IEC 364 must be complied with. If
not, there is a risk of causing serious personal injury and damage to property. The valid, applicable national, local and
system-specific regulations and requirements must be observed.
Intended use
The motors have been designed in accordance with DIN VDE 0530.
The use of motors in potentially explosive areas falling under danger zone 1 is not permitted without certification of
conformity (observe supplementary instructions).
The power rating given for the motors is for ambient temperatures up to +40°C and for installation altitudes = 1000 m
above sea level. Use under other ambient conditions may be possible under certain circumstances subject to consultation
with the manufacturer of the motor or fan.
Electrical connection
Connection may only be carried out with the system disconnected from the power supply.
The system must be secured to prevent it being switched on again!
In particular, the fan must also be secured to prevent it being started up again accidentally!
The information on the rating plate, the connection diagram in the connection box and the additional information in the
Installation instruction of the manufacturer must be observed.
To ensure that the electrical connection provides lasting safety, the connection work must be carried out in accordance
with the motor manufacturer's Installation instruction.
Observe the tightening torques for the terminal board connections. These can be found in the motor manufacturer's
Installation instruction.
It must be ensured that neither foreign bodies and dirt or moisture get into the terminal box. Cable inlets which are not
required need to be sealed off with blank plugs to make them dust-tight and watertight. When you close the terminal box,
make sure that the seal on the cover of the terminal box is fitted correctly.
The mains voltage and mains frequency must be identical with the values given on the rating plates for the motor. Motors
with wide voltage winding can be operated with different mains voltages. In this case you have to check whether the
available mains voltage is covered by the voltage range given on the motor's rating plate. Where 60 Hz mains systems
are concerned, an additional plate may be attached by the fan manufacturer which tells you that the motor may also be
operated with 50 Hz on a 60 Hz mains system.

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The arrangement of the jumpers on the terminal board is dependent on the available mains voltage (see illustration).
Winding circuit in
Positions of the jumpers on the

terminal board
Two examples for winding constructions and operating voltages:

Winding construction 230 V:
Operating voltage: 230 V / 400 V 50 Hz

460 V 60 Hz /
220-240 V / 380-420 V 50 Hz
440-480 V 60 Hz

460 V / 60 Hz /
380-420 V / 660-725 V 50 Hz
440-480 V / 60 Hz
The protective earth conductor has to be connected to the

terminal.

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9.2 Housing
The grey cast iron housings can be rotated through 45 degrees. This means that other housing positions (except 225°)
can also be set retrospectively without changing the direction of rotation of the impeller.
If the direction of rotation is changed from anti-clockwise to clockwise or the reverse, the same housing parts can be
used. Only the intake-side housing and the motor stand have to be swapped over. Attention: The impeller has to be
replaced.
The condensate drainage nozzle (only provided if ordered) located is at the lowest point on the housing and is sealed
with a plug. Before placing into operation and during operation, the nozzle has to be opened if necessary to allow any
condensation which has collect to drain away. Never allow the impeller to start up in condensation as this could lead to
damage and unbalance.
The fan housings have a flange connection with threaded holes on the intake side and a connection flange with through
holes on the pressure side.
9.3 Impeller
The impeller of the MVG (heavy duty) design made of St 02 Z material is equipped with blades which are bent forwards
and which is mounted overhung on the motor shaft.
The impeller of the MVGR design made of St 02 Z material is equipped with blades which are bent backwards and
which is mounted overhung on the motor shaft.
The impeller of the MVGK design made of 1.0347 material is equipped with blades which are bent backwards and
which is mounted overhung on the fan shaft.
The maximum permissible speed (specified on the rating plate on the fan) must never be exceeded
under any circumstances!
9.4 Seal at the shaft exit
The housing is sealed at the shaft exit by a felt ring in the motor-side housing cover. Leakage losses should be low.
Version with a mechanical seal
The housing is sealed at the shaft exit by a mechanical seal. The mechanical seal is comprised of the seal face
compartment, compression spring, thrust ring, two O-rings and the seal face. The rotating seal face is pressed against
the sealing face of the vertical seal face compartment in the axial direction by the springs.
9.4.1 MVGR fans
9.4.1.1 Belt drive
The drive is provided by a V-rope drive. The belts are electrically conductive in accordance with ISO R 1813 and thermally
resistant from -55°C to +70°C.
 Before placing into operation, the V-belts have to be re-tensioned to the values given below (see chapter 16)!
 The V-belts have to be checked after a short running-in period of about 15 minutes and re-tensioned if necessary.
 Check the V-belt after 3 days and re-tension again if necessary, or even earlier depending on operating conditions.
 Check the V-belt after 10 days again, or even earlier depending on operating conditions.
 The belt tension needs to be checked at greater intervals on a regular basis.
A belt testing device must be used for testing and tensioning.
9.4.2 MVGK fans

The drive shaft is supported in roller bearings with grease valves in a bearing head which is flange-mounted on the fan
housing.
The fan shaft is supported by a double-bearing casing with grease lubrication. The fan shaft is supported at two bearing
points which are both mounted together in a single bearing casing.

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9.4.2.1 Coupling
The fan coupling compensates for radial, axial and angular shaft displacements between the fan and motor. The ring-
shaped rubber elements, which are subjected to tangential forces, transfer the torque.
Supplier : Flender
Coupling type : N-EUPEX
Coupling size : B 80
Ambient temperature (max.) : 80 [°C]
9.4.2.2 Cooling impeller

To dissipate the heat which is transferred from the fan by the shaft, a cooling impeller is clamped to the shaft behind the
shaft seal.
This cooling impeller is of multi-piece design. The shaft seal can be accessed by removing the cooling impeller.
For trouble-free operation, it is essential that the cooling impeller is tightly fastened. If it is not fastened
tightly enough, the cooling impeller could work loose and fly off, which could cause serious injuries!
For safety reasons the insulation provided by the customer must be installed before placing into
operation to ensure that the cooling impeller protection cannot be covered!

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10 Items supplied and temporary storage
Check the delivery for completeness in accordance with the delivery note when it arrives. Any missing parts and/or
transport damage must be reported immediately in writing.
The fan has to be protected against penetration by moisture and dust and against inadmissible vibrations from the
foundations. Measures must be taken to prevent the influence of strong fluctuations in temperature. Failure to observe
the above could lead to damage to electric motors, cable terminal boxes, bearings, coats of paint and seals, etc., as well
as corrosion, and therefore a higher risk of ignition as a consequence.
For temporary storage the fan must be stored in its transportation packing.
11 Information on transportation
The cast fans (MVG and TVG) do not have any slinging points on the fan housing. The eye-bolt on the motor must not
be used for transporting the fan as a complete unit. To transport the fan, a strap has to be wrapped around the motor
housing (between the drive side of the fan and the terminal box for the motor). The strap is prevented from slipping on
an axial basis by the terminal box.
The fan may only be lifted and transported by persons who have read this Installation instruction, have understood the
specified safety regulations, accident prevention regulations and instructions concerning the transportation of the fan,
and are familiar with the hoisting gear and required lifting tackle.
11.1 Safety information for transportation
Observe the safety information for transportation!
 Transportation and lifting on site is the responsibility of the customer and should be carried out by qualified
personnel.
 Accident prevention regulations must be complied with.
 Do not move the load over people.
 The fans may only be lifted and transported by the fixtures provided for the purpose.
 If the hoisting gear has sufficient load capacity, it can be used to lift the complete fan for transporting on site.
 Care must be taken when lifting the fan to ensure that no parts get damaged by the carrying ropes.
 Prevent the fan from bumping into anything, as this will case damage.
 The carrying ropes and harnesses must be suitable for the weight of the fan.
 Do not let the fibre ropes get tangled.
 Do not let ropes and chains get twisted.
 Suspension elements must be able to move freely on the load hook.
 Wear personal protective equipment (helmets, gloves, etc.).
 Transport eye-bolts on motors must not be used for lifting the fan as a complete unit.
 The fan has to be lifted and lowered gently in order to avoid causing any damage.
 The manufacturer cannot accept any liability for damages caused by transportation on site.
11.2 Transport instructions
Lift and transport the fan using suitable lifting tackle only!
 Care must be taken when lifting the fan to ensure that no parts get damaged by the
lifting tackle!
 The cast fans (MVG and TVG) do not have any slinging points on the fan housing. The
eye-bolt on the motor must not be used for transporting the fan as a complete unit. To
transport the fan, a strap has to be wrapped around the motor housing (between the
drive side of the fan and the terminal box for the motor). The strap is prevented from
slipping on an axial basis by the terminal box.

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11.2.1 MVGK fans
Lift and transport the fan using suitable lifting tackle and slings only, at the transport eye-bolts
and/or lifting lugs intended for the purpose!
Observe the following diagram!
Permissible load directions

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 The fans may only be lifted and transported by the fixtures provided for the purpose. Do
not attach lifting tackle and slings to bearings, intake and pressure nozzles, motors or
other components!
 It is imperative that you make sure that you use lifting tackle and slings with the same
lengths and that the weight is distributed evenly. The angle must not exceed 25°! See
the previous diagram.
lifting tackle and slings. Use a carriage if necessary!

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12 Installation
 For outdoor installation, the installation phase itself and any repair work undertaken outdoors, suitable measures
must be taken to protect the fan against the elements.
 Check that the installation point is flat and clean.
 The installation tolerance for the alignment of the machine with
a greased bearing of max. 2 mm/m

must be observed.
 Immediate alignment is of critical importance to prevent damage to the bearings, vibrations and other defects!
 Strain on the fan at the connections caused by the pipe lines is not permitted and it is essential that this is prevented.
Strain could cause changes in the gap on the nozzle. This is likely to lead to rubbing of the impeller nozzle and
therefore an increased risk of explosion in explosive environments.
 If the machines are installed in a fixed position, the foundations must be expertly produced in accordance with DIN
4024, Part 2, and the machine secured in accordance with our recommendations. The requirements of DIN 18800
must be observed for all installations steel structures.
 Restoring forces from pipe lines must be restricted to a minimum, for example by using compensators. Where
maximum loads for nozzles are specified in the dimension sheet, these must never be exceeded. Pipe lines must
have specified fixed reference points.
This applies in particular to machines with media with a temperature over 100°C.
 The fan must be mounted on the foundations without strain.
 If installation is on vibration dampers, it is a requirement that compensators are fitted on the intake- and pressure-
side flange. This also applies to all other supply lines to the fan (condensate drainage nozzles, steam and oil supply
systems).
 Fasten vibration dampers at the intended points as shown in the installation layout drawing. If different types of
vibration damper are used, make sure that these are arranged in accordance with the installation layout drawing.
 If it emerges during installation that the machine has a slight tilt, an adjustment plate has to be fitted to the appropriate
vibration damper between the damper and the foundations.
 After completion of alignment, the dampers have to be secured to the foundations by screws or dowels. In certain
cases it will be sufficient if just the corner dampers are secured.
 The fan and motor must be properly and expertly earthed via the earth connections provided for the purpose.
 The fan components or supply systems must be capable of expanding freely in response to rising temperatures,
without coming into contact with combustible substances or materials.

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13 Placing into operation / test run
* No liability will be accepted for faults caused by inexpert placing into operation by the customer.
* Check whether lubricants have been filled up. The bearings must not be started without lubrication!
* Only specified lubricants, or equivalent, may be used. Contamination is not permitted.
* Before placing into operation, check that there are no foreign bodies in the pipe lines or the fan housing.
* Foreign bodies are not permitted to enter the impeller.
* The surge-like entry of liquids into the impeller and inadequate removal of condensation from the fan housing must
be prevented under all circumstances.
* Before the test run, check that the shaft is able to rotate easily and that the impeller moves freely (for explosion-
protected fans, check and document the impeller gap).
* Check the direction of rotation (there are direction arrows on the housing).
* Check that all mechanical and electrical safety equipment is properly fitted and installed.
* Check that the current type, voltage and frequency of the drive motor are suitable and that the connections have
been made in accordance with standards.
* Check that all guards have been correctly installed with original parts, including means of fastening.
* The materials and processing and operating materials used must be suitable for the intended use and must be
compatible with the medium.
Before it is placed into operation, the fan must be fitted with one or more EMERGENCY STOP command
devices for averting an immediate danger which has actually occurred or threatens to occur.
These devices must be clearly marked and must be accessible without difficulty at all times!
It must only be possible to release the EMERGENCY STOP command device by means of appropriate
actuation. This release function must not cause the fan to be restarted; it may only make it possible for
a restart to be carried out.

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14 Switching on the fan
The fan may only be started up if the moment of acceleration is sufficient over the entire start-up
range up to the rated speed!
Start up the fan with the flow restrictor closed.
Operation with a closed flow restrictor is only permissible during fan start-up. The flow restrictor
must be opened quickly as soon as the final speed has been reached!
Check the following points during and after the start-up of the fan:
* Power consumption
* Voltage
* Smooth running of the fan (vibrations)
* Unusual running noise
* Bearing temperatures
* Compression heat on the fan housing
If any of the specified values are exceeded or the fan makes unusual noises, switch off the fan
immediately and inform the manufacturer's service department.
15 Switching off the fan
Let the fan slow down to a stop without braking.
Observe safety regulations in accordance with DIN VDE 0105.
The fan must never be switched on again until the impeller has come to a complete standstill first.
This is the only way of preventing negative torque shocks which could cause considerable damage
to components such as bearings, impellers and couplings.
The fan is only permitted to be switched on and off by specialists who have been assigned to do so by the person
responsible for the system.

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16 Servicing and maintenance
Accident prevention regulations must be observed!
The usual mechanical engineering principles must be observed in relation to maintenance. Only suitably qualified
personnel are permitted to carry out any maintenance and repair work.
The customer must ensure that there is sufficient space available for maintenance and repair work. This applies both in
terms of service personnel and in terms of space for setting down parts of the fan such as impellers and the housing, etc.
Furthermore, constructional measures have to be provided to enable these parts to be lifted and moved, e.g. crane tracks
or beams for attaching chain hoists. The customer must also provide adequate lighting for servicing and maintenance
work, and must also take suitable measures to prevent falling. Guide mandrels are to be used for maintenance and repair
work.
Carry out maintenance and repair work using suitable protective equipment and tools only.

Ear protection may have to be worn for work on the system, depending on the surrounding noise
levels.



Safety glasses have to be worn for work on the system, depending on the specific activity.

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The fan needs to be checked every now and again for smooth running during operation. If the impeller does not run
smoothly, it needs to be cleaned and possibly rebalanced.
Before you open the fan housing, undo a flange connection or remove the mesh guard, the fan
must be switched off and measures taken to prevent it being switched on again. Make sure that
the impeller is at a standstill.
Verify that it is disconnected from the power supply. Cover or safeguard adjacent live
components.
Accident prevention regulations must be observed. All safety equipment must be re-installed
before the fan is switched on again!
Check that all hot surfaces have cooled down sufficiently!
Risk of burn injuries caused by removing insulation or opening service openings too quickly.
If the system is shut down for any lengthy period of time (longer than 3 months), the rotor unit needs to be
turned in 2-weekly cycles in order to ensure that the roller bearings are kept covered in lubricant and to prevent
point loading of the roller bearings!
Harmful and hazardous residual substances in the machine must be taken into account!
Use suitable cleaning agents and equipment for cleaning work!
The use of high-pressure steam cleaners for cleaning the fan is not permitted!
It is imperative that moisture is prevented from getting into components such as bearings and seals,
since this could lead to the development of corrosion.
After completion of maintenance and repair work, check that all solid and liquid foreign bodies have
been removed from the fan and adjacent system components, that all openings have been closed, and
that all mechanical and electrical safety equipment has been fitted back in place.
If any damage should occur in spite of observing all instructions and information, please report it immediately. The next
steps, subject to agreement:
* request for a service engineer, or

* repair or production of a new one at our factory
The following inspections and maintenance work need to be carried out in a general service:
16.1 MVG fans
16.1.1 Motor
The motor manufacturer's instructions must be observed for all care and maintenance work on the motor.
If the electric motor is equipped with a re-lubrication device, the specific information on the plate attached to the motor
must be observed!
16.1.2 Housing
Inspection of the housing (once a year) for the possible presence of:
* Damage / cracks!

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16.1.3 Impeller
Inspection of the impeller (once a year) for the possible presence of:
* Wear
* Damage / cracks!
* Corrosion
* Temper colours
* Balancing weights ( secure fastening, wear )!
The manufacturer must be informed if any unusual changes are found.
16.1.4 Shaft seal

Check the felt ring (once a year) for:
* Dirt
* Wear
16.1.5 Tightening torque

If no special tightening torque values are given in the installation layout drawing or in the dimensions sheet, the tightening
torque values given in the following table apply:
Quality 8.8
20 oC 100 oC 200 oC 250 oC 300 oC
Thread
(Nom. diam) FM (N) Ma (Nm) FM (N) Ma (Nm) FM (N) Ma (Nm) FM (N) Ma (Nm) FM (N) Ma (Nm)
M6 5930 8 5467 7 5004 7 4726 6 4448 6
M8 10848 19 10000 18 9153 16 8644 15 8136 14
M 10 17236 38 15889 35 14543 32 13735 30 12927 28
M 12 25094 65 23134 60 21173 55 19997 52 18821 49
M 16 47117 155 43436 143 39755 131 37546 124 35338 117
M 20 73527 303 67782 280 62038 256 58592 242 55145 228
M 24 105938 523 97662 482 89385 441 84420 417 79454 392
M 30 168874 1042 155681 960 142488 879 134572 830 126656 781
M 36 246420 1805 227169 1664 207917 1523 196366 1439 184815 1354
M 42 338576 2885 312125 2659 285673 2434 269803 2299 253932 2163
M 48 445342 4342 410550 3558 375757 3664 354882 3460 334006 3256
The clamping force FM gives the permissible bolting force, based on utilisation of the yield strength Rp0.2 of 90%.
The tightening torque Ma is based on the method of tightening using a torque wrench, alpha=1.8 and a coefficient of
sliding friction of 0.08 for the head and thread friction.
16.1.6 Checking the screw connections

All screw connections must be regularly checked to ensure that they are all in place and securely fastened, e.g.:
* Screw connections on the housing
* Screw connections on the compensators
* Screw connections on the foundations
* Fastening of the bearing housing/motor, etc.
16.1.7 Checking for leaks

Check the fan housing and connected pipe line for leaks and, if required:
* Tighten the flange connection
* Check the shaft seal and replace if necessary
* Re-seal the joints

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16.1.8 Storage and corrosion protection instructions

Karl Klein Ventilatorenbau GmbH does not specify any requirements as a general rule for corrosion protection
for temporary storage at the building site. The customer needs to take appropriate measures of protection to
provide protection against the elements.
If the fan is to be put into storage and provided with protection against corrosion for a temporary storage period of a
maximum of 3 months, the following must be observed:
* Close the intake and pressure opening

* Protect machine parts without paintwork by applying conserving agent to them
* To prevent damage to the bearings, the rotor unit needs to be turned every now and again.
* Take appropriate measures (cover with foil or store in solid buildings) to protect the fan against the elements
* Ensure that it is protected from rain and frost

* To prevent moisture and wetness infiltrating from behind or gap corrosion where weld seams are not
complete on both sides, apply a filler of suitable materials to seal any such points.
* The surfaces of shafts and shaft nuts made of normal steel which do not have a protective coating must
be given a covering coat of corrosion protection wax. The shaft has to be protected with a coating of oil-
resistant lacquer in the bearing housing.
* Shaft exits on bearings have to be wrapped with Denso tape (wax-soaked jute tape).
* Stuffing boxes and packings have to be wrapped with Denso tape (wax-soaked jute tape) on the outside.
A film of Molykote has to be applied to the mating surfaces of bushes which may be susceptible to
corrosion.
* The housings of fitted labyrinth shaft seals must be treated with a long-term preservative such as Tectyl
No. 506.
* Shaft exits on shaft seals have to be wrapped with Denso tape (wax-soaked jute tape).
* Mechanically machined surfaces on impellers must be sealed with corrosion protection.
* Corrosion protection must be applied to impellers without paintwork or other form of coating.
* Corrosion protection wax must be applied to exposed bushes if they are made of non-rust-resistant
materials.
* Motors must be provided with protection against corrosion in accordance with the supplier's instructions.
If the fan is to be put into storage and provided with protection against corrosion for period of more than 6 months, the
following must be observed:
* The application of protective coatings with corrosion protection wax must be repeated.
* Denso tape which is in place must be pressed on again with no gaps after racing the machine.
If there should be longer periods of standstill after placing into operation during the warranty period, Karl Klein
Ventilatorenbau GmbH must be informed so that special instructions can be drawn up for protection against
corrosion. If we are not informed, we cannot accept any claims under the guarantee for later damages resulting
from improper storage.
16.1.9 Removal of protection against corrosion

Prior to placing into operation, the:
* Denso tape
* corrosion protection wax on mating surfaces and, depending on the process conditions, on the process
side (e.g. fan housing),
have to be removed.

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16.2 MVGR fans
16.2.1 Motor
must be observed!
16.2.2 Housing
* Damage / cracks!
16.2.3 Impeller
* Wear
* Damage / cracks!
* Corrosion
* Temper colours
16.2.4 Shaft seal

* Dirt
* Wear
16.2.5 Bearing
The bearing has to be removed after approx. 40,000 operating hours in order to remove the grease which has collected
in the housing as a result of re-lubrication.
Type Amount of grease per bearing Re-lubrication interval [h]

[cm3]
MVGR 3 7-9 1000
MVGR 5 10 - 12 1000
MVGR 7 10 - 12 1000
Grease type: Shell Alvania RL3 or equivalent grease from another manufacturer.
16.2.6 Belt drive

Check the belt drive at regular intervals for:
* Wear
* Alignment
* Belt tension
If you need to re-tension or replace the belt, pay attention to the following:
1. Always replace the complete V-belt set, never just individual belts!
2. First slacken the belts, i.e. slacken the tensioning screws and the screws used to secure the motor. Shift the
motor sufficiently to allow the belts to be removed and fitted without tension.
3. Fit the new belt set and pre-tension slightly. Check the parallelism of the belt pulleys with a ruler and correct if
necessary.
4. The belts have to be tensioned enough for the specified thumb deflection depth to be achieved with the specified
test force. The values apply to the individual belt. Afterwards, tighten the screws for securing the motor. The V-
belts have to be re-tensioned after a running-in period of about 15 minutes. After three and ten days of operating
conditions, the V-belts need to be checked again and re-tensioned again if necessary. The belt tension needs to
be checked at greater intervals on a regular basis because slippage as a result of insufficient tension will lead to
the premature destruction of the belt.
5. A belt testing device from a belt manufacturer must be used for testing and
tensioning.

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Type Speed [rpm] Test force [N] Thumb deflection

depth [mm]
MVGR 3 4060 25 5,5
4640 25 5,5
5220 25 5,5
5800 25 5,5
6500 25 4,5
7250 25 4,0
MVGR 5 4060 25 5,5
4640 25 5,5
5220 25 5,5
5800 50 7,5
6500 50 6,5
MVGR 7 3620 25 7,5
4060 25 6,0
4640 50 8,0
5220 50 8,0
Table: Test force and thumb deflection depth in dependency on fan type and speed

Quality 8.8
20 oC 100 oC 200 oC 250 oC 300 oC
Thread
M6 5930 8 5467 7 5004 7 4726 6 4448 6
M8 10848 19 10000 18 9153 16 8644 15 8136 14
M 10 17236 38 15889 35 14543 32 13735 30 12927 28
M 12 25094 65 23134 60 21173 55 19997 52 18821 49
M 16 47117 155 43436 143 39755 131 37546 124 35338 117
M 20 73527 303 67782 280 62038 256 58592 242 55145 228
M 24 105938 523 97662 482 89385 441 84420 417 79454 392
M 30 168874 1042 155681 960 142488 879 134572 830 126656 781
M 36 246420 1805 227169 1664 207917 1523 196366 1439 184815 1354
M 42 338576 2885 312125 2659 285673 2434 269803 2299 253932 2163
M 48 445342 4342 410550 3558 375757 3664 354882 3460 334006 3256



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Karl Klein Ventilatorenbau GmbH does not specify any requirements as a general rule for corrosion protection for
temporary storage at the building site. The customer needs to take appropriate measures of protection to provide
protection against the elements.

* Slacken the V-belt on machines with a belt drive

* Apply a coating of oil-resistant lacquer to the insides of bearing housings and covers and grease slingers
if grease-lubricated bearings are used.
corrosion.
No. 506.
* Corrosion protection must be applied to the profiles or mating surfaces of belt pulleys if machines with belt
drives are used.
materials.

* Denso tape
have to be removed.

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16.3 MVGK fans
16.3.1 Motor
must be observed!
16.3.2 Housing
 Damage / cracks!
Water collects in the bottom part of the housing when the impeller is cleaned and as a result of condensation. This water
has to be drained through the condensate drainage nozzle.
16.3.3 Impeller
* Wear
* Damage / cracks!
* Corrosion
* Temper colours
16.3.4 Bearing
Re-lubrication interval: Every 3,000 h (min. twice a year)
Grease type: Shell Alvania R3
Type Initial lubrication Re-lubrication

per bearing point [cm3] per bearing point [cm3]
MVGK 7 79 8
16.3.5 Shaft seal

Check the shaft seal (once a year) for:
* Dirt
* Wear or damage to the seal disc and the carbon ring
* Wear on the compression spring
Each shaft seal should be dismantled once a year during the fan inspection to enable the seal discs to be cleaned and
inspected.
The amount of wear permitted on the carbon ring is approx. 2.5 mm, as defined by the cylindrical part of the carbon ring.
When the conical part is reached, it is imperative that the carbon ring be replaced.

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16.3.6 Coupling drive

The manufacturer's Installation instruction must be observed!





 Close the intake and pressure opening

 Protect machine parts without paintwork by applying conserving agent to them
 To prevent damage to the bearings, the rotor unit needs to be turned every now and again.
 Slacken the V-belt on machines with a belt drive
 Take appropriate measures (cover with foil or store in solid buildings) to protect the fan against the elements
 Ensure that it is protected from rain and frost

 To prevent moisture and wetness infiltrating from behind or gap corrosion where weld seams are not
 The surfaces of shafts and shaft nuts made of normal steel which do not have a protective coating must

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 Apply a coating of oil-resistant lacquer to the insides of bearing housings and covers and grease slingers
 Bearings lubricated with oil must be filled to the overflow with corrosion protection oil, e.g. Anticorit OHK or
equivalent, and then the oil must be drained again after the machines have been raced a number of times
to produce a corrosion protection film.
 Shaft exits on bearings have to be wrapped with Denso tape (wax-soaked jute tape).
 Stuffing boxes and packings have to be wrapped with Denso tape (wax-soaked jute tape) on the outside.
corrosion.
 The housings of fitted labyrinth shaft seals must be treated with a long-term preservative such as Tectyl
No. 506.
 Shaft exits on shaft seals have to be wrapped with Denso tape (wax-soaked jute tape).
 Mechanically machined surfaces on impellers must be sealed with corrosion protection.
 Corrosion protection must be applied to impellers without paintwork or other form of coating.
 Corrosion protection must be applied to the profiles or mating surfaces of belt pulleys if machines with belt
drives are used.
 Corrosion protection wax must be applied to exposed bushes if they are made of non-rust-resistant
materials.
 Corrosion protection must be applied to the couplings on coupling machines.
 For coupling machines with hydraulic couplings, follow the supplier's instructions.
 For fans with vane controllers, throttle valves and adjusting devices, corrosion protection has to be applied
to the shaft exits of the blades and flaps and to the joints from both the inside and the outside. The
adjustment mechanism must not be blocked.
 For adjusting devices, follow the supplier's instructions.
 Gear units must be provided with protection against corrosion in accordance with the supplier's instructions.
In this connection, check the transmission oils used for compatibility with the residual corrosion protection.
 Motors must be provided with protection against corrosion in accordance with the supplier's instructions.
 The application of protective coatings with corrosion protection wax must be repeated.
 Bearings with oil lubrication need to be provided with fresh protection against corrosion.
 Denso tape which is in place must be pressed on again with no gaps after racing the machine.

 Denso tape
 corrosion protection wax on mating surfaces and, depending on the process conditions, on the process
have to be removed.
 Bearings with oil lubrication have to be flushed with the oil to be used later in order to eliminate any
possibility of contamination with corrosion protection oil. This is to be followed by filling with the stipulated
amount of oil.


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Quality 8.8
20 oC 100 oC 200 oC 250 oC 300 oC
Thread
M6 5930 8 5467 7 5004 7 4726 6 4448 6
M8 10848 19 10000 18 9153 16 8644 15 8136 14
M 10 17236 38 15889 35 14543 32 13735 30 12927 28
M 12 25094 65 23134 60 21173 55 19997 52 18821 49
M 16 47117 155 43436 143 39755 131 37546 124 35338 117
M 20 73527 303 67782 280 62038 256 58592 242 55145 228
M 24 105938 523 97662 482 89385 441 84420 417 79454 392
M 30 168874 1042 155681 960 142488 879 134572 830 126656 781
M 36 246420 1805 227169 1664 207917 1523 196366 1439 184815 1354
M 42 338576 2885 312125 2659 285673 2434 269803 2299 253932 2163
M 48 445342 4342 410550 3558 375757 3664 354882 3460 334006 3256

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Faults and troubleshooting
ATTENTION: The work described below must always be carried out by specialist personnel in compliance with
the applicable safety regulations. To prevent damage caused by work which is carried out inexpertly, you should
always have repair work carried out by our qualified specialist personnel.
Karl Klein Ventilatorenbau GmbH will not accept any warranty claims for damage caused by repair work carried
inexpertly.
Fault Possible cause Solution
The fan does not operate smoothly Caking on the impeller Clean the impeller.
Attention: Clean the impeller only
when it is at a standstill. The fan must
be secured to prevent it starting up
again during this time!
The impeller is worn. Replace the impeller.
The impeller has become deformed Replace the impeller.

as a result of thermal influences.
Strain on the fan as a result of Undo the foundation fasteners and

uneven foundations. level the foundations.
Secure the fan again afterwards.
Correct the settings.

Inexpertly adjusted/secured vibration
dampers.
Medium escaping from the shaft seal. The deal is faulty or worn. Replace the seal.
Grinding noises on the fan. Impeller rubbing against the intake Undo the housing cover and realign
nozzle. it; check the pipe line if necessary
and correct it.
Check the motor for bearing damage;

Noises from the motor. replace the bearing if necessary.
The power consumption given on the Excessive air flow. Reduce the air flow with the
rating plate is permanently exceeded. assistance of a flow restrictor until the
permissible power consumption level
is achieved.
Different speed for 60 Hz mains Check the frequency.

system.
The fan fails to start. The drive motor is not connected Check the connection.
correctly.
Reduce the switch-over time for star

With a star-delta starter, the motor to delta.
gets stuck in the star.
Close the flow restrictors.

Starts up against insufficient system
resistance.
The cross-sectional area of the cable
The motor safety device is too weak. and the safety equipment protect the
starting current during start-up.
Close the flow restrictors; check the

The start-up time is too long. torque MA/MN.
Check the motor and replace/repair if

The drive motor is faulty. necessary.

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16.4 MVGK fans
Bearing damage
Failure to operate smoothly Damage to rings and rolling elements. Replace the bearing.
Excessive bearing clearance.
Wear as a result of dirt or insufficient

lubrication Clean the bearing to remove dirt. Use
clean grease or oil. Observe the
intervals for changing the oil and re-
lubricating.
Unusual running noise:

Insufficient operational clearance.
Whining or whistling noise. Use bearings with more operational
clearance.
Unsuitable lubricant.
Rattling or irregular noise. Select the right type of lubricant.
Gradual change in the running noise. Change in the operational clearance

caused by temperature influences. Protect bearings against temperature
Damage to the rolling surface (e.g. influences.
caused by dirt or fatigue)
Coupling damage
Failure to operate smoothly The coupling halves are not aligned. Check the alignment in accordance
with the instructions of the coupling
manufacturer.
Elastic elements are worn.
Replace the elastic coupling
elements.
Elastic elements are too soft.
Use harder elastic coupling elements.

The motor torque is to high MA/MN elements.
Severe jolting during start-up Star-delta starter
16.5 MVGR fans
Bearing damage


lubricating.

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clearance.

Belt drive damage

Pronounced vibrations. The belt is too loose or too tight. Correct the tension of the belt.
Loud noises. Impeller rubbing against a nozzle. Correct the tension of the belt.
The belt is too loose or too tight. Correct the tension of the belt.
Incorrect belt selection. Replace the belt.
The belt is oily or dirty. Clean the belt or replace if

necessary.
The belt is worn.
Replace the belt.

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17 Disassembly
Disassembly of the fan to relocate it to a different installation location or if it is to be scrapped.
The disassembly of the fan may only be carried out by specialists who, on the basis of their professional training,
experience and instruction, have sufficient knowledge of safety regulations, accident prevention regulations and generally
recognised codes of practice (e.g. VDE guidelines, DIN standards). The specialists must be capable of assessing the
work they have been assigned to do, recognising and preventing potential hazards, and be authorised to undertake the
necessary work and activities by the individual responsible for the safety of the system.
18 Disposal
Parts and components of the fan which have reached the ends of their service lives, e.g. due to wear, corrosion,
mechanical strain, fatigue and/or any other action which cannot be directly ascertained, have to be properly and correctly
disposed of in accordance with national and international laws and regulations after disassembly. The same applies to
all operating materials such as oil and grease or any other materials and substances. The conscious or unconscious
reuse of used parts such as impellers, roller bearings, V-belts, etc., could pose a risk of danger to persons, harm to the
environment and damage to plant and machinery.
Collect all oil, grease and cloths/cotton waste soiled with oil and grease in suitably marked
containers and dispose of them in accordance with regulations.

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19 Spare parts
Stocks of key spare parts and wearing parts need to kept at the installation point of the system; this is a requirement for
ensuring that the fan is always in proper working order and ready for operation.
We only offer a guarantee for the genuine spare parts supplied by us.
We explicitly point out that all spare parts and accessories not supplied by us have also not been tested and approved
by us. The installation and/or use of such products can therefore, under certain circumstances, lead to negative changes
in the specified constructional characteristics of the device or system and therefore result in the compromising of active
and/or passive safety.
Karl Klein Ventilatorenbau GmbH will not accept any liability or warranty claims for damage caused by the use of non-
genuine spare parts and accessories.
Please note that special production and supply specifications often apply to in-house parts or parts from other
manufacturers and we always ensure that the spare parts we offer you are the state-of-the-art in technology and comply
with the latest statutory requirements.
When you order spare parts, it is essential that you quote the
VA number
Machine number
Part name
ID number
Item number
Order quantity
when you do so.
The machine number can be found on the rating plate on the fan.
Please address all enquiries and orders to the following address:
Karl Klein Ventilatorenbau GmbH Waldstr. 24

D-73773 Aichwald
Tel.: +49 711 36-906-0
Fax: +49 711 36-906-950 Germany
E-mail: [email protected]

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Radial Gussventilator / Radial cast fan MVG
Bei Ersatzteilbestellung bitte Maschinen-Nr. angeben!

Please quote the machine no. when ordering spare parts!
Teil / part Benennung / signification

10 Motor komplett / motor complete
60 Gehäuse / casing
70 Deckel / cover
80 Dichtung / gasket
120 Filzring / felt ring
130 Laufrad / impeller
140 Druckscheibe / pressure disc
180 Deckel / cover

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Radial Gussventilator / Radial cast fan TVG


70 Deckel / cover
180 Deckel / cover

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Mounting and dismounting of the fan-casing
Dismounting
1. Loosen and remove the 8 hexagon screw (M8) for the cover
2. Remove the cover
3. Remove the gasket
4. Loosen and remove the 8 hexagon screw (M8) for the motor-flange
5. Remove the fan-casing
It is not necessary to dismount the motor and impeller!
Mounting
The assembling is done in reverse order!

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20 Declaration of incorporation of partly completed machinery

Spare-part-list
High Pressure Fan
60
50
70
80
90 100 10 20 30
Legend Spare Parts List High Pressure-Fan
Position No. description

10 housing complete
20 fan wheel
30 inlet nozzle
40 suction wire mesh guard
50 motor flange
60 motor complete
70 Disc
80 Socket
90 Slice x2
100 Felt ring
1. Ordering instructions for spare parts
A clear identification and naming of the parts ensures the delivery of the correct spare part. To avoid
delivery errors and extensive description, only specify the terms and numbers listed in the parts list.
Order address:
Set up your spare parts orders:
FA. Karl Klein Ventilatorenbau GmbH

Waldstraße24
D-73773 Aichwald
Tel.: 0711 – 36906-0
Fax.: 0711 – 36906-50
Seite 1|1
Stand: 10/19
G:\TB\DOKUMENTATIONEN\Ersatzteillisten
8. Armaturen
8. Valves

Commission-N°:
7001021687
Factory-N°:
4020004 Project:
TIMOR 1
Drawing-N°:
BB2285A
Baujahr: Pos.-Nr.:
Datenblätter und Betriebsanleitungen

Datasheets and Operating Instructions
Anzahl/ Hersteller/ Typ/ Nennweite/ Material/ Antriebsart/ Benennung/
ANA-Pos KKS-No. /Tag-No.
Quantity Manufacturer Type Size material Type of drive designation
11MAM65AA005
9 11MAM65AA010 3 JASTA GD-6 3" 150# Body 1.4301 notch lever Butterfly Valve
11MAM65AA020
11MAM65AA510
11 2 RITAG ZRK3 3" 150# SS wafer type Check Valve
11MAM65AA520
11MAM60AA010 Body A105N
12 2 AVA Alms 1D00222 1" 150# hand wheel Globe Valve
11MAM60AA030 seat 13Cr
13 11MAM60AA020 1 GESTRA UNA 45 1/2" Body A105N -- float steam trap
Kommissions-Nr.: Auftraggeber:
Commission-No.:
F220-3511 Siemens Energy Global GmbH & Co. KG
Customer:

7001021687
Quantity/discription: Order-No.:
Factory-No.:
4020004 TIMOR 1
Project:
Zeichnung-Nr.: Projekt-Nr.:
Drawing-No.:
67-3265 BB285A
Project-No.:
Baujahr: Pos.-Nr.:
2021 --
Pos.-No.:
Pos. 9
11MAM65AA005 /
11MAM65AA010 /
11MAM65AA020
Butterfly Valve
Type GD-6
2 Technical Description
Butterfly Valve Type GD-6 with mounted pneumatic actuator
Exploded view of a standard GD-6 with a swing through cast-iron disk and a pneumatic actuator.
GD-6
Technical Description 3
Technische Beschreibung
General Description of the Butterfly Valve Type GD-6
The GD-6 butterfly valve is one of our all-rounders With our three sided jacketed sealing gasket we can
in the fields of control valve technology and shut-off implement an impermeability of at least 99,95% at
valve technology. They are clamped between flanges high pressure when compared to fully opened valve
(PN-6 to PN-16) in pipelines. We can produce this disks.
valve from any materials available on the market,
depending on the application (temperature, ele- We do not only offer our valves with free end-
ment, pressure). Custom made orders and customer shafts, but can also upon requests offer the valves
requests are always possible after consultation. either as manually operated (with locking mecha-
nism or continuously variable fine adjustment) or
Special valves which have already been imple- an actuator. Any actuator available on the market
mented are a water-cooled GD-6 valve and a lever can be fitted with our DIN ISO 5211 mounting kit.
system valve that allows multiple valves to be cont- Any further adaption is possible depending on the
rolled at once. customer’s request.
Advantages at a glance
Handling Easy, depending on the accessories
Impermeability 99%, 99,8% and 99,98% compared to fully opened disk
Temperature Application -100°C to +1100°C
Element Compatibility Design and material selection according to your element and further
operating conditions, including: (aggressive) flue gas, dust laden elements,
biogas or exhaust gases from biomass burning
Reliability Very low possibility of failure
Maintenance Characteristics Low maintenance
GD-6
Basic Information
Sizes: DN 15 – DN 2000 implemented as a standard
Up to DN 5000 possible as a custom order
GD-6 as an intermediate flange design to clamp between flanges according to

DIN EN 1092-1, PN-6/PN-10/PN-16
ANSI B 16.5 – 150 lbs / 300 lbs / 400 lbs
Every clamping possibility available upon request
Centering aid guarantees an exact fitting in the pipeline
Operation
With free shaft-ends
Manual operation with a grid handle with locking mechanism or continuously variable fine adjustment
A corresponding shaft adaption with the DIN ISO 5211 mounting kit
With an attached actuator (pneumatic, electric or hydraulic)
Shaft Seal
Gland seal
O-Rings or shaft seals (EPDM, FPM, NBR, PTFE)
Smooth running seal
TA-Luft
Shaft Bearing
Friction bearing (EN-GJL-250, RG7, Rhyolite, PTFE, DU)
External fitting through flange bearings for smooth operating
External fitting over a friction bearing (EN-GJL-250CrNi-bearing blocks) for high temperatures up to 1100°C
Impermeability classes
Approx. 99% impermeability in a swing through design
Approx. 99% impermeability (metallic sealing) compared to fully opened valve disk in a design with a stop bar
in the body
Approx. 99,98% impermeability (with flexible seal) in designs with a stop bar and three sided jacketed gasket
in the body
Temperature Application
From -100°C to +1100°C
Material
Cast iron (e.g. EN-GJL-250, EN-GJL-250CrNi, 1.4848, 1.4865)
Steel (e.g. S235JR, S355JR)
Stainless steel (e.g. 1.4301, 1.4541, 1.4571, 2.4610)
Heat resistant steel (e.g. 1.4828, 1.4841)
Aluminium
Duplex
GD-6
Closing Types
Swing through 99% impermeability compared to fully opened disk
With a stop bar in the body 99,5% to 99,8% impermeability compared to fully opened disk
With stop bar and gasket seal 99,95% to 99,98% impermeability compared to fully opened disk
With sealing air Up to 100% impermeability
Material Combinations
Temperature up to 350°C from 350°C- 450°C from 450°C- 550°C from 550°C - 750°C from 750°C-
1100°C
Body EN-GJL-250; EN-GJL-250; EN-GJL-250CrNi; EN-GJL-250CrNi, 1.4828
Alu EN-GJL-250CrNi; 1.4301; 16Mo3
P265GH
Disk EN-GJL-250; EN-GJL-250; 1.4301; EN-GJL- 1.4541; 1.4828
St. 37; 1.4301 1.4301; P265GH 250CrNi; 16Mo3 EN-GJL-250CrNi
Shaft St. 37; 1.4021 1.4021; 1.4541 1.4021; 1.4305; 1.4541 1.4541 1.4828
Subject to modification
Note: The material combinations listed here are standard combinations. The exact selection is made for special designs and
special requests in accordance with specifications or after consulting with you.
Actuators and Actuator Accessories

Operation Accessory
Manual operation Grid handle, fine adjustment, worm gear
Pneumatic actuator Magnet valve, electro-mechanical end switch, inductive proximity switch
positioner 4...20mA, PROFIBUS, HART, etc.
Elektric actuator End switch, revolution off-switch, position encoder 4…20mA, positioner,
PROFIBUS, HART
Security functions Fast closing and opening <1 sec through express airing or fall weights
Cylinder Magnet valve, End position control
Advantages of the GD-6

Our valves are individually produced according to your needs. They are adjusted one hundred percent accor-
ding to the operational conditions. That includes the specifications, material choice and operation.
The Kv-values, impermeability and dynamic torque are according to our standards and tested in an FEM si-
mulation. Here the advantages are shown between cast disks and steel disks when it concerns the imperme-
ability of the disk.
The intermediate flange design GD-6 is produced with a centering aid. This ensures easy installation and cen-
tering the valve between the flanges of the pipeline.
GD-6
6 References
References
BÜTTNER Gesellschaft für Trocknungs- und Umwelttechnik mbH, Krefeld
Loesche ThermoProzess GmbH, Gelsenkirchen
Riedhammer GmbH, Nürnberg
„ We are using to sell them to kilns and oven manufacturers that use the valves on
smokes and hot air plants. In every situation your valves have given very good
results and the customers have been always satisfied of the products.
We hope you will go on to make your valves like you are doing now.
R. Bovo / Econex, Italy
Application Areas
Smelters, foundries, cement factories, crematoriums, industrial ovens (for iron, steel, aluminium and stainless
steel), glass factories, factories (for Rockwool, porous concrete etc.), ceramic ovens, drying and dust extractors,
gas turbines, heat treatment, and high temperature oven construction.
Our delivery supply range: Sensors according to determination of the mass flows. Our flow measurement
sensors measure independently from pressure, temperature and element. Further information upon request.
GD-6
Technical Data 7
Standard Measurements GD-6 with Grid Handle
DN B C D d G H approx. Mass [kg]

15 25 60 44 8 100 130 1
20 25 60 44 8 100 130 1,1
25 25 75 60 10 100 145 1,2
32 25 80 67 10 100 150 1,4
40 25 83 75 10 145 163 1,5
50 25 85 85 10 145 165 1,6
65 30 95 105 12 145 175 2,2
80 30 105 120 12 145 185 2,5
100 30 115 140 12 145 195 2,8
125 35 135 170 12 145 215 4,8
150 40 150 195 15 155 235 5,7
175 40 165 225 15 155 250 7,5
200 40 175 255 15 155 260 8,8
225 40 185 280 15 155 270 11,5
250 40 220 310 15 155 305 13,9
300 45 240 360 20 155 325 22,6
350 45 290 415 25 210 410 27
400 50 335 465 30 210 455 39
450 50 360 520 30 210 480 45
500 55 400 570 30 210 520 56
550 60 420 620 30 210 540 78
600 65 460 675 30 210 580 82
GD-6
8 Technical Data
Standard Measurements GD-6 with Fine Adjustment SFD-6

15 25 60 44 8 100 130 1
20 25 60 44 8 100 130 1,1
25 25 75 60 10 100 145 1,2
32 25 80 67 10 100 150 1,4
40 25 83 75 10 145 163 1,5
50 25 85 85 10 145 165 1,6
65 30 95 105 12 145 175 2,2
80 30 105 120 12 145 185 2,5
100 30 115 140 12 145 195 2,8
125 35 135 170 12 145 215 4,8
150 40 150 195 15 155 235 5,7
175 40 165 225 15 155 250 7,5
200 40 175 255 15 155 260 8,8
225 40 185 280 15 155 270 11,5
250 40 220 310 15 155 305 13,9
300 45 240 360 20 155 325 22,6
350 45 290 415 25 210 410 27
400 50 335 465 30 210 455 39
450 50 360 520 30 210 480 45
500 55 400 570 30 210 520 56
550 60 420 620 30 210 540 78
600 65 460 675 30 210 580 82
GD-6
Technical Data 9
Standard Measurements GD-6 with Fine Adjustment RDST-32

15 25 60 44 8 255 165 1
20 25 60 44 8 255 165 1,1
25 25 75 60 10 255 180 1,2
32 25 80 67 10 255 185 1,4
40 25 83 75 10 255 188 1,5
50 25 85 85 10 255 190 1,6
65 30 95 105 12 255 200 2,2
80 30 105 120 12 255 210 2,5
100 30 115 140 12 255 220 2,8
125 35 135 170 12 255 240 4,8
150 40 150 195 15 255 255 5,7
175 40 165 225 15 255 270 7,5
200 40 175 255 15 255 280 8,8
225 40 185 280 15 255 290 11,5
250 40 220 310 15 255 325 13,9
300 45 240 360 20 290 365 22,6
350 45 290 415 25 290 420 27
400 50 335 465 30 290 465 39
450 50 360 520 30 290 490 45
500 55 400 570 30 290 530 56
550 60 420 620 30 290 550 78
600 65 460 675 30 290 590 82
700 70 495 780 35 400 657 120
800 75 545 880 40 400 707 180
900 80 600 980 40 400 762 220
1000 90 670 1080 45 400 832 240
1100 90 730 1180 45 400 892 295
1200 90 790 1295 45 400 952 345
1400 110 920 1510 50 Drive 1120 Contract specific
GD-6
10 Technical Data
Standard Measurements GD-6 with Free Shaft and Fitting
DN B C D d H approx. Mass [kg]

15 25 60 44 8 140 1
20 25 60 44 8 140 1,1
25 25 75 60 10 155 1,2
32 25 80 67 10 160 1,4
40 25 83 75 10 163 1,5
50 25 85 85 10 165 1,6
65 30 95 105 12 175 2,2
80 30 105 120 12 185 2,5
100 30 115 140 12 195 2,8
125 35 135 170 12 225 4,8
150 40 150 195 15 240 5,7
175 40 165 225 15 255 7,5
200 40 175 255 15 265 8,8
225 40 185 280 15 275 11,5
250 40 220 310 15 320 13,9
300 45 240 360 20 340 22,6
350 45 290 415 25 420 27
400 50 335 465 30 465 39
450 50 360 520 30 490 45
500 55 400 570 30 530 56
550 60 420 620 30 550 78
600 65 460 675 30 590 82
700 70 495 780 35 625 120
800 75 545 880 40 675 180
900 80 600 980 40 730 220
1000 90 670 1080 45 820 240
1100 90 730 1180 45 880 295
1200 90 790 1295 45 940 345
1400 110 920 1510 50 1070 Contract specific
GD-6
Technical Data 11
Standard Measurements GD-6 with ISO 5211 Mounting Kit
DN B C D d E approx. Mass [kg]

15 25 60 44 8 200 ( 160 ) 2,4
20 25 60 44 8 200 ( 160 ) 2,5
25 25 75 60 10 200 ( 160 ) 2,6
32 25 80 67 10 200 ( 160 ) 2,7
40 25 83 75 10 200 ( 160 ) 2,8
50 25 85 85 10 200 ( 160 ) 2,9
65 30 95 105 12 200 ( 160 ) 3,6
80 30 105 120 12 200 ( 160 ) 3,9
100 30 115 140 12 200 ( 160 ) 4,3
125 35 135 170 12 200 ( 160 ) 6,1
150 40 150 195 15 200 ( 160 ) 7,7
175 40 165 225 15 200 ( 160 ) 9,8
200 40 175 255 15 200 ( 160 ) 11,2
225 40 185 280 15 200 ( 160 ) 12,9
250 40 220 310 15 200 ( 160 ) 16,4
300 45 240 360 20 200 ( 160 ) 23,3
350 45 290 415 25 200 ( 160 ) 31,9
400 50 335 465 30 200 ( 160 ) 44,1
450 50 360 520 30 200 ( 160 ) 47
500 55 400 570 30 200 ( 160 ) 64,6
550 60 420 620 30 200 ( 160 ) 82
600 65 460 675 30 200 ( 160 ) 84
700 70 495 780 35 200 ( 160 ) 122
800 75 545 880 40 200 ( 160 ) 184
900 80 600 980 40 200 ( 160 ) 224
1000 90 670 1080 45 200 ( 160 ) 256
1100 90 730 1180 45 200 ( 160 ) 311
1200 90 790 1295 45 200 ( 160 ) 361
1400 110 920 1510 50 Contract specific Contract specific
GD-6
12 Technical Data
Standard Measurement GD-6 with Double External Bearing
DN B C D d K H approx. Mass [kg]

15 - - - - - - -
20 - - - - - - -
25 25 75 60 10 160 315 8,6
32 25 80 67 10 160 320 8,8
40 25 83 75 10 160 323 8,9
50 25 85 85 10 160 325 9
65 30 95 105 12 160 335 9,6
80 30 105 120 12 160 345 9,9
100 30 115 140 12 160 355 10,2
125 35 135 170 12 160 385 12,2
150 40 150 195 15 160 400 13
175 40 165 225 15 160 415 15
200 40 175 255 15 160 425 16
225 40 185 280 15 160 435 19
250 40 220 310 15 160 480 21
300 45 240 360 20 160 500 30
350 45 290 415 25 160 580 46
400 50 335 465 30 160 625 58
450 50 360 520 30 160 650 64
500 55 400 570 30 160 690 75
550 60 420 620 30 160 710 97
600 65 460 675 30 160 750 101
700 70 495 780 35 160 785 139
800 75 545 880 40 160 835 200
900 80 600 980 40 160 890 230
1000 90 670 1080 45 160 980 260
1100 90 730 1180 45 160 1040 320
1200 90 790 1295 45 160 1100 370
1400 110 920 1510 50 200 1270 Contract specific
GD-6
Technical Data 13
Kv-values of the GD-6
α [°] DN 50 DN 65 DN 80 DN 100 DN 125 DN 150 DN 200 DN 250 DN 300

5° 1 2 3 4 6 9 16 26 37
10 ° 2 3 5 8 12 18 31 49 70
15 ° 4 6 9 14 22 32 57 88 127
20 ° 6 9 14 22 35 50 89 139 201
25 ° 8 14 21 32 50 72 128 201 289
30 ° 11 18 28 44 68 98 175 273 393
35 ° 14 24 37 58 90 130 231 361 520
40 ° 19 32 48 76 118 170 302 472 680
45 ° 25 42 63 98 154 222 394 616 886
50 ° 32 54 82 129 201 290 515 804 1158
55 ° 42 71 108 169 263 379 674 1054 1518
60 ° 55 93 142 221 346 498 885 1383 1991
65 ° 73 123 186 290 453 653 1160 1813 2610
70 ° 95 160 243 380 593 854 1519 2373 3417
75 ° 123 208 315 492 769 1108 1969 3077 4431
80 ° 166 281 425 665 1039 1496 2659 4155 5984
85 ° 207 349 529 827 1292 1861 3308 5169 7443
90 ° 227 384 582 909 1420 2045 3635 5680 8179
5° 50 65 83 102 147 200 261 331 408
10 ° 96 125 158 196 282 384 501 634 783
15 ° 173 226 286 353 509 693 905 1145 1414
20 ° 273 357 452 558 803 1093 1428 1807 2231
25 ° 393 514 650 803 1156 1573 2055 2600 3210
30 ° 536 699 885 1093 1574 2142 2798 3541 4372
35 ° 708 925 1171 1446 2082 2833 3701 4684 5782
40 ° 926 1209 1530 1889 2720 3702 4835 6120 7555
45 ° 1206 1576 1994 2462 3546 4826 6303 7977 9849
50 ° 1576 2059 2606 3217 4632 6305 8235 10423 12867
55 ° 2066 2698 3414 4215 6070 8262 10791 13658 16861
60 ° 2711 3540 4481 5532 7966 10842 14161 17923 22127
65 ° 3553 4641 5874 7251 10442 14213 18564 23494 29005
70 ° 4651 6075 7688 9491 13668 18603 24298 30752 37966
75 ° 6031 7878 9970 12309 17725 24126 31511 39881 49236
80 ° 8144 10637 13463 16621 23934 32577 42549 53852 66483
85 ° 10131 13232 16746 20675 29771 40522 52927 66986 82699
90 ° 11132 14540 18402 22718 32714 44527 58158 73607 90872
Please contact us should you need the valves in larger sizes.
GD-6
14 Custom Designs
Custom Designs
According to your individual needs, we produce the GD-6 in different material combinations and for different
actuators and applications.
GD-6 GD-6 GD-6

With side mounted Reduced Brush valve
actuator diameter for flow elements
Glossary
Butterfly Valve A butterfly valve consists of a body and is for flow regulation. Clamped between flanges.
Centering Aid Lugs right and left of the operating side shaft outlet of the valve. They ensure easier and more
precise installation into a pipeline.
Closing Contact of the valve disk with the body. Possible seals: Striking, swing through, with stop bar
and stop bar with seals.
Coupling Connection between the actuator and the valve shaft.
Electric Operation Electric operation of the valve. Control over 4 .. 20 mA-signal possible. Wide ranging optional
accessories available.
Element Element flowing through the valve. (Gas, liquid, etc.)
External Seal Used at high temperatures to guarantee the turning of the valve at all operating conditions.
Fine Adjustment Lever which has a free swing variance of 90° and is movable per wing screw or clamp lever into
any position.
Fitting Key Metallic adaption of the shaft to the actuator. This is a side connected metal lug on the shaft.
Serves for power transfer from the actuator to the shaft.
Flange Bearing Serves as transmission of high torques.
Four Cornered Shaft Serves for the adaption of the shaft to the required connection of the actuator.
Grid Handle Gear teeth on a nut screwed scale provides the possibility of a gradual adjustment of the valve
disk. The catch of the hand lever locks into the teeth. 16 positions between 0 and 90 ° are fixed.
Hand Operation With grid handle, fine adjustment or worm gear. Depending on installation.
Hydraulic Operation Operates with a hydraulic cylinder. Special: Good power distribution in limited spaces.
Impermeability Shows how impermeable the flow is inside the valve. (Dependant on construction, classified in
leakage rates).
GD-6
Glossary 15
Inner Sizing Internal flow area of the valve.
Installation Position Describes the horizontal or vertical position of the shafts of the valve once installed.
ISO 5211 Norm regulates the attachment measurements for actuators to attachment parts onto valves.
Kv 90° Flow in a fully open valve disk.
Lever System It regulates two or more valves with an actuator.
Mounting Kit Normed part for mounting actuators.
Nominal Size Size of the inner measurement of the valve.
Operation Operation of the valve. Possible operation: manual, pneumatic- und electric actuators
(as standard). All further adaptions available as per customer needs.
Operational Pressure Pressure in the pipeline which works on the valve.
Operational Temperature Temperature of the element in the pipeline.
Packing Gasket Serves as the seal between the valve and shaft exit from the valve body. Can be produced in
various ways. (EPDM, PTFE, TA-Luft eg.)
Pneumatic Operation Opening of the disk in the valve with a pneumatic actuator. With or without a spring setting.
Control possible with a positioner.
RDST-32 Infinitely adjustable fine adjustment for larger valves.

Safety Position This is decided by the customer. Defines the position of the valve in an emergency.
Seal Flexible material in the valve. To improve the impermeability.
Sealing Air Used to seal the shaft up to 100%.
Service Defines the regular necessary readjustments (readjustment of the packaging, etc.).
For the maintenance plan please see operating and maintenance manual.
SFD-6 Infinitely adjustable fine adjustment with a manual handle, used in smaller valves.
Shaft Bearing Bears of the shafts in the body.
Slide Bearing Turned sleeve, e.g. from red brass.
Step-seated Disk valve fitted in the body of the valve and stops the flow.
Stop bar Metallic valve stop in the valve. Serves to seal the valve.
Swing-through Valve without seals between the disk and body with defined ring gap.
TA-Luft German Clean Air Act (§48 BImSchG). Using a TA-Luft packing ensures 100% seal of the shaft
bushing to the outside.
GD-6
16
Certificates
We are certified for the following processes:
ISO 9001
AD 2000 HP0
EN 3834-2
SIL
ATEX
Services for the Valves

We are happy to support you with various services
to optimize the use of the valve.
Determination of sound level

Expertise on earthquake safety
Strength calculation
FEM calculation Test station at JASTA-ARMATUREN
Leakage calculation
Flow simulations
Assembly and test run of your actuator
Lacquering to your liking
JASTA-ARMATUREN GmbH & Co. KG
Levinstr. 156-160
45356 Essen
Germany
Phone: +49 - (0)201 - 86602-0

Fax: +49 - (0)201 - 86602-21
www.jasta-armaturen.com
[email protected]
GD-6
Pos. 11
11MAM65AA510 /
Valve Experience. 11MAM65AA520
Made in Germany.
Zwischenflansch-Rückschlagklappe ZRK 3
Wafer Type Swing Check Valve
Einsatzgrenzen (Pressure / Temperature Ratings)
TMA (°C) -200 -10 100 200 300 400

class 150 PMA (bar) 16 16 14 11 10 9
Leckrate G (met., PTEE) bzw. Leckrate A (NBR, EPDM, FKM) nach EN 12266-1
Leakage G (met., PTEE) resp. leakage A (NBR, EPDM, FKM) acc. to EN 12266-1
Werkstoffe (Materials)
Gehäuse / Body Platte / Disc

Stainless Steel / Edelstahl Stainless Steel / Edelstahl DN 2“ - 20“
class 150
Elastische Dichtung möglich – Einsatzgrenzen siehe Technische Informationen: Dichtungen Verwendung

Elastic seat rings available – operating limitations see Technical Information: Seat Rings
• Flüssigkeiten
• Dämpfe
• Gase
• Fluidgruppe 1 gemäß
DGRL 2014 / 68 / EU
Öffnungsdrücke (Opening Pressures)
Application
• Fluids
DN PÖ (mbar) • Steam
• Gas
• Fluidgroup 1 acc. to
2“ ~0 8 PED 2014 / 68 / EU
2 ½“ ~0 8
Bei Einsatz in Prozessanlagen
3“ ~0 8
verwenden Sie bitte unsere
4“ ~0 8 Type ZRD.
5“ ~0 8 For applications in process plants
6“ ~0 8 please select our type ZRD.
8“ ~0 12
10“ ~0 12
12“ ~0 12
14“ ~0 15
16“ ~0 16
18“ ~0 16
20“ ~0 22
= Durchflussrichtung / Flow direction

Technische Änderungen vorbehalten 08/2017
Technical modifications reserved 08/2017
RITAG Ritterhuder Armaturen GmbH & Co. Phone +49 (0) 47 95-5 50 42-0
Armaturenwerk KG Fax +49 (0) 47 95-5 50 42-850 1
Sachsenring 30 eMail: [email protected]
D-27711 Osterholz-Scharmbeck Internet: www.ritag.com
Valve Experience.
Made in Germany.
Maße und Gewichte (Dimensions and Weights)
Maße / dimensions in mm
DN L D A d0 d1 kg
(cl. 150)
2“ 20 101 42 26 62 1,3
2 ½“ 20 120 55 38 78 1,6
3“ 20 133 60 42 95 1,9
4“ 20 171 80 70 118 2,3
5“ 21 193 100 92 140 3,4
6“ 22 219 120 114 172 4,5
8“ 29 274 155 143 228 8,5
10“ 34 336 200 185 271 13,0
12“ 38 406 232 214 296 20,0
Baulänge in Anlehnung an API 6D
14“ 44 447 271 263 360 26,0 Face / Face dimension acc. to API 6D
16“ 51 511 310 305 405 36,0
18“ 60 546 360 342 440 61,0 Passend zwischen Flansche ASME B16.5RF
For fitting between flanges acc. to ASME B16.5RF
20“ 64 603 400 400 500 85,0
Druckverlustdiagramm (Pressure Drop Chart)
Die Diagrammwerte gelten für Wasser bei 20°C. Sie resultieren aus
Messungen an Ventilen beim Einbau in horizontaler Leitung. Beim Einbau
in vertikaler Leitung ergeben sich im Teilöffnungsbereich unbedeutende
Abweichungen. Um Druckverrluste bei anderen Medien zu ermitteln, ist
zuvor der äquivalente Wasservolumenstrom nach folgender Formel zu
berechnen:
Graph readings apply to water at 68° F (20° C). They result from
measurements on valves installed in horizontal pipes.
For installation in vertical pipes insignificant devitations occur
in the partial opening. In order to determine pressure losses for
other media the equivalent water flow has to be calculated before
applying the following formula:
. . ρ
VW = V
1000
.
VW [m3/h] äquivalenter Wasservolumenstrom
equivalent water flow
[kg/m3] Dichte des Mediums (Betriebszustand)
. density of medium at working conditions
V [m3/h] Volumenstrom des Mediums (Betriebszustand)
flow of medium at working conditions Technische Änderungen vorbehalten 08/2017
Armaturenwerk KG Fax +49 (0) 47 95-5 50 42-850
Pos. 12
11MAM60AA010 /
11MAM60AA030
Technische Änderungen vorbehalten/Subject to technical alterations
1)
ASME-Faltenbalgventil Class 150, verschweißter Deckel, Regulierkegel B.F.E. FIG. 1JHWL 300
1)
ASME Bellows Sealed Globe Valve Class 150, welded bonnet, plug type disc B.F.E. FIG. 1JHWL 300
D
12
13 Werkstoffe/Materials:
11 1 Gehäuse/Body 1.0460 ~ A105N
10 2 Oberteil/Bonnet 1.0460 ~ A105N

8
3 Kegel/Disc 13Cr
9 4 Sitzring/Seat ring 13Cr stellitiert/stellited
H (geöffnet/open)
2 7 5 Spindel/Stem 13Cr
6 Faltenbalg/Bellows 1.4571 ~ A182-F316Ti
nach TA-Luft/VDI 2440
acc. TA-Luft/VDI 2440 7 Stopfbuchspackung/Gland packing Graphit(e)
5 (low emission execution)
Stopfbuchsbrille/Gland flange
8 A105N ~ 1.0460
9 Stopfbuchshülse/Gland follower 13Cr
6
10 Stopfbuchsschrauben/Gland bolts A2-70
11 Stopfbuchsmuttern/Gland nuts A2-70
12 Spindelmutter/Stem nut 13Cr
B 4)
13 Handrad/Handwheel Stahl/Steel
4
1
3)
L
Maße/Dimensions:
Nennweite/Size 1/2" 3/4" 1" 1.1/2" 2"
L 3) 108 117,5 127 166,5 203
H (geöffnet/open) 170 175 205 260 300
D 88 88 97 138 172
B 4) 89 98,5 108 127 152,5
Gewicht ca./Weight approx. kg 3,0 3,8 5,5 10,3 17,6
2)
Drehmoment/Torque Nm * * * * *
AVA-Artikel-Nr./-Item-No. 1N00220 1N00221 1N00222 1N00223 1N00224
Baulängen , Anschlüsse: Face to face dimensions , Connections:

3) 3)
Baulängen nach ASME B16.10 Face to face dimensions acc. ASME B 16.10
4) 4)
Flanschmaße nach ASME B 16.5 Flanges acc. ASME B 16.5
Dichtleiste RF/SF (Ra = 3,2 - 6,3 µm) Flange face finish RF/SF (Ra = 3,2 - 6,3 µm)
Bemerkungen: Remarks:
1) 1)
Armatur nach BS 5352, DGRL 2014/68/EU, AD 2000 A4, Valve acc. BS 5352, PED 2014/68/EU, AD 2000 A4, TA-Luft 2002/VDI 2440,
TA-Luft 2002/VDI 2440, NACE sauergasbeständig, ATEX 2014/34/EU NACE sour gas resistant, ATEX 2014/34/EU
2) 2)
Die angegebenen Drehmomente sind max. Drehmomente The shown torques are max. torques for clean water at ambient temperature
für Medium Wasser bei Raumtemperatur
* *
Auf Anfrage On request
Rev.-Nr./Rev.No.: Datum/Date: Best.-Nr./Order No.: Ident.-Nr./Tag No.:
5/RB 02.02.2017
ARMATUREN VERTRIEB HOLTERKAMP 1 TEL.: +49 2102/4390-0 [email protected]

ALMS GMBH D-40880 RATINGEN FAX: +49 2102/4390-99 WWW.AVA-ALMS.DE
Pos. 13
Data Sheet 819345-03
11MAM60AA020 Issue Date: 03/17
Ball Float Steam Trap

UNA 45, UNA 46, UNA 46A
PN 40/Class 300
DN 15, 20, 25, 40, 50, 65
Description The different equipment versions allow you to adjust the flow
direction of the equipment to the flow pattern of your installa-
Float traps type UNA 45 are designed for removing conden-
tion. The flow arrow must correspond to the direction of the
sate from steam or compressed air.
fluid flow. The following positions of installation are possible:
Float traps type UNA 46 and UNA 46A are designed for remo-
ving condensate from steam or other gases / gas mixtures.
UNA 45 hl, UNA 46 hl, UNA 46A hl
Equipment fitted with control unit SIMPLEX and SIMPLEX-P
is operated and controlled by the float and the rolling ball.
Equipment with this type of control unit is particularly suitable v
for cold condensate and cold distillates. v
v
The rolling ball of the control unit SIMPLEX-P is made of
Perbunan® rubber, which ensures tight shut-off of the seat.
Equipment with control unit DUPLEX may also be used for “v” for installation in vertical pipework with downward flow
air venting the installation. This type of control unit is parti-
cularly suitable for saturated steam systems. The control unit
DUPLEX consists of a float operated rolling ball valve and a
temperature dependent air-venting facility. Do not expose the hl
membrane regulator capsule of the DUPLEX control unit to hl
UNA 45 hl Sightglass cover hl
superheat conditions above 5 K.
By means of the externally adjustable internal bypass it is
possible to adjust a bypass passage that flows past the
control unit. “hl” for horizontal left
The equipment must only be used within the allowable pres-
sure and temperature limits and only if the chemical and
corrosive influences on the equipment are taken into account. hr
hr
hr
Function
The control unit opens the orifice as a function of the liquid
level. A rising level results in a proportional opening of the
equipment. The max. discharge capacity depends on the “hr” for horizontal right
orifice size when the ball is completely lifted off its seat and
the orifice is fully open.
Materials
UNA 45 hl Cover for mounting electrodes Optional extras Component
Type EN ASTM
part
Vent hole and drain hole
Float-lifting lever allows the float to be manually lifted UNA 45,
1.0460 A105
(for purging any dirt away from the seat area) Body UNA 46
Hand-vent valve allows manual air-venting the pipeline UNA 46A 1.4404 A182-F316L
Strainer
UNA 45
Horizontal flow direction (hr) from left to right sightglass
(when viewed from the body end) cover /
5.3103 A3951)
Control unit SIMPLEX-P with Perbunan® rolling ball cover for
Externally adjustable inner bypass Cover installing
electrodes
Sightglass cover PN 16/CL 150
Special cover for installing measuring electrodes UNA 46 1.0619 A216-WCB
NRG 16-19 or NRG 16-27
UNA 46A 1.4408 A351-CF8M
End connections Body gasket,

control all Graphite CrNi
Flange EN 1092-1 B1 PN 40 unit gasket
Flange ASME B 16.5 Class 150 RF, 300 RF
Other
Screwed sockets G: ISO 228/1 all Stainless steel
components
Screwed sockets NPT: ASME B 16.11
1) Physical and chemical properties comply with EN grade.
Socket-weld ends to DIN EN 12760
ASTM nearest equivalent grade is stated for guidance only.
Socket-weld ends ASME B 16.11 Class 3000
Butt-weld ends via transition pieces to EN 12627, welded
joint geometry ISO 9692-1 code number 1.3 (30° chamfer)
Butt-weld ends via transition pieces ASME B 16.25
ASME B 36.10
1
Components UNA 45, UNA 46, UNA 46A Item no. Designation
2 3 27 4 2 Body
13 3 Body gasket
4 Control unit SIMPLEX
13 Hand-vent valve
16 Float-lifting lever
18 Control unit DUPLEX
Control unit SIMPLEX-P with Perbunan®
19
rolling ball
Control unit DUPLEX with externally
20
adjustable internal bypass
27 Gasket
28 Control membrane
Socket spanner 16
28 18 19 20
Dimensions and weights
H2
X H2
H H
L
L
H1
H1
X
B B
UNA 45, UNA 46, UNA 46A L1 UNA 45, UNA 46, UNA 46A
Control unit DUPLEX Control unit DUPLEX
with flanged ends with screwed connections
X
Externally adjustable
internal bypass
Space required for servicing
To remove the cover a withdrawal space S of 240/350 mm

(depending on size) is required.
If the supplied socket spanner is attached to the equipment
an additional clearance of 100 mm is required.
S
2
Equipment with flanges EN 1092-1 PN 10–40

DN 15 DN 20 DN 25 DN 40 DN 50 DN 65
Nominal size
(½") (¾") (1") (1½") (2") (2½")
Overall length L [mm (in)] 150 (5.9) 160 (6.3) 230 (9.1) 290 (11.4)
B [mm (in)]
Standard cover 171 (6.7) 287 (11.3)
Sightglass cover 213 (8.4) 333 (13.1)
Cover for mounting electrodes 186 (7.3) 306 (12.0)
H1 [mm (in)] 60 (2.4) 107 (4.2)
H2 [mm (in)] 90 (3.5) 1) 151 (5.9) 1)
Total height H [mm (in)] 150 (5.9) 1) 258 (10.2) 1)
Width L1 [mm (in)] 110 (4.3) 2) 170 (6.7) 2)
X [mm (in)] 13 (0.5)
Weight [kg]
Standard cover 6.8 7.3 7.8 24.8 26.2 28.6
Sightglass cover 9.7 10.2 10.7 30.5 31.9 34.3
Cover for mounting electrodes 8.5 9.0 9.5 28.0 29.4 31.8
Weight [lb]
Standard cover 15.0 16.1 17.2 54.7 57.8 63.1
1) If equipped with hand-vent valve add 25 mm (1 in).
2) If equipped with float-lifting lever or bypass add 35 mm (1.4 in).
Equipment with flange ASME B16.5 Class 150/300

DN 15 DN 20 DN 25 DN 40 DN 50 DN 65
Nominal size
(½") (¾") (1") (1½") (2") (2½")
Overall length L [mm (in)] 150 (5.9) 160 (6.3) 241 (9.5) 267 (10.5) 292 (11.5)
B [mm (in)]
Standard cover 171 (6.7) 287 (11.3)
H1 [mm (in)] 60 (2.4) 107 (4.2)
H2 [mm (in)] 90 (3.5) 1) 151 (5.9) 1)
Width L1 [mm (in)] 110 (4.3) 2) 170 (6.7) 2)
X [mm (in)] 13 (0.5)
Weight Class 150
Weight [kg]
Standard cover 6.2 6.6 7.2 23.8 25.9 29.4
Weight [lb]
Standard cover 13.7 14.6 15.9 52.5 57.1 64.8
Weight Class 300
Weight [kg]
Standard cover 6.6 7.4 8.2 26.0 27.5 31.1
Weight [lb]
Standard cover 14.6 16.3 18.1 57.3 60.6 68.6
3
Dimensions and weights – continued –
Equipment with socket-weld end, butt-weld end via transition pieces

DN 15 DN 20 DN 25 DN 40 DN 50 DN 65
Nominal size
(½") (¾") (1") (1½") (2") (2½")
95 (3.7) 165 (6.5) 267 (10.5) 292 (11.5)
Overall length L [mm (in)]
(Socket-weld end) (Butt-weld end via transition pieces EN, ASME)
B [mm (in)]
Standard cover 171 (6.7) 287 (11.3)
H1 [mm (in)] 60 (2.4) 107 (4.2)
H2 [mm (in)] 90 (3.5) 1) 151 (5.9) 1)
Width L1 [mm (in)] 110 (4.3) 2) 170 (6.7) 2)
X [mm (in)] 13 (0.5)
Weight [kg]
Standard cover 5.3 5.2 21.2 21.9 24.6
Sightglass cover 8.2 8.1 26.9 27.6 30.3
Cover for mounting electrodes 7.0 6.9 24.4 25.1 27.8
Weight [lb]
Standard cover 11.7 11.5 46.7 48.3 54.5
Equipment with screwed socket

DN 15 DN 20 DN 25 DN 40 DN 50
Nominal size
(½") (¾") (1") (1½") (2")
Overall length L [mm (in)] 95 (3.7) 165 (6.5)
B [mm (in)]
Standard cover 171 (6.7) 287 (11.3)
H1 [mm (in)] 60 (2.4) 107 (4.2)
H2 [mm (in)] 90 (3.5) 1) 151 (5.9) 1)
Width L1 [mm (in)] 110 (4.3) 2) 170 (6.7) 2)
X [mm (in)] 13 (0.5)
Weight [kg]
Standard cover 5.3 5.2 5.1 21.2 20.9
Weight [lb]
Standard cover 11.7 11.5 11.2 46.7 46.1
Equipment with butt-weld end via transition pieces

DN 15 DN 20 DN 25 DN 40 DN 50 DN 65
Nominal size
(½") (¾") (1") (1½") (2") (2½")
B [mm (in)]
Standard cover 171 (6.7) 287 (11.3)
H1 [mm (in)] 60 (2.4) 107 (4.2)
H2 [mm (in)] 90 (3.5) 1) 151 (5.9) 1)
Width L1 [mm (in)] 110 (4.3) 2) 170 (6.7) 2)
X [mm (in)] 13 (0.5)
Weight [kg]
Standard cover 5.6 5.7 21.3 21.6 22.5
Weight [lb]
Standard cover 12.3 12.6 47.0 47.6 49.6
4
Pressure & temperature ratings Operating data
The values indicated in the following tables apply to standard equipment. Equipment with sightglass cover:
Note that the type of end connection used may restrict the use of the equipment to below the pressure/temperature limits PN 16: max. service temperature 240 °C at
quoted. 12.3 bar service pressure
All equipment specific values are indicated on the nameplate. Class 150: max. service temperature 240 °C at
12.4 bar service pressure. If the pH value
is above 9.0 and the fluid temperature
Limiting conditions for UNA 45 and UNA 46: Flange PN 40, screwed sockets G, exceeds 200 °C the glass will wear down
butt-weld ends EN faster.
Equipment with measuring electrode
Pressure1) p [barg] 40 37.1 33.3 27.6 25.7 13.12)
NRG 16-19 or NRG 16-27,
Temperature1) T [°C] –10/20 100 200 300 350 4502) PN 40/Class 300: max. service temperature 238 °C at
32 bar service pressure
Equipment with control unit SIMPLEX-P
Max. admissible differential pressure [bar] 2, 4, 8, 13, 22, 32
with Perbunan rolling ball:
ΔPMX [psi] 29, 58, 116, 188, 320, 465 max. service temperature 40 °C at ΔPMX
16 bar.
Admissible service temperature Control unit DUPLEX: Saturated steam temperature plus 5 K
Equipment with control unit DUPLEX:
The max.service temperature corresponds
to the saturated steam temperature +5 K.
Pressure1) p [psig] 580 538 483 400 373 1902)
Temperature1) T [°F] 14/68 212 392 572 662 8422)
1) Resistance limits of body/cover to EN 1092-1
2) Not for UNA 45
Limiting conditions for UNA 45 and UNA 46: Flange Class 150
Pressure1) p [barg] 19.6 17.7 13.8 10.2 8.6 5.52)
Temperature1) T [°C] –29/20 100 200 300 345 4252)
Max. admissible differential pressure [bar] 2, 4, 8, 13 (19,6 bar with orifice (AO) 22, 32)
ΔPMX [psi] 29, 58, 116, 188 (284 psi with orifice (AO) 22, 32)
Pressure1) p [psig] 285 260 200 140 125 802)

Temperature1) T [°F] – 20/100 200 400 600 650 8002)
1) Resistance limits of body/cover to ASME B 16.5
2) Not for UNA 45
Limiting conditions for UNA 45 and UNA 46:

Flange Class 300, screwed socket NPT, socket-weld end, butt-weld end ASME
Pressure1) p [barg] 51.1 46.6 43.8 39.8 37.8 28.82)
Temperature1) T [°C] –29/20 100 200 300 345 4252)

ΔPMX [psi] 29, 58, 116, 188, 320, 465
Pressure1) p [psig] 740 280 635 570 550 4102)

Temperature1) T [°F] – 20/100 200 400 600 650 8002)
2) Not for UNA 45
Limiting conditions for UNA 45 with sightglass cover: flange PN 16, screwed sockets G,
butt-weld ends EN
Pressure1) p [barg] 16.0 14.8 14.0 13.3 12.3
Temperature1) T [°C] –10/20 100 150 200 240
Max. admissible differential pressure [bar] 2, 4, 8, 13, (16 bar with orifice (AO) 22, 32)
ΔPMX [psi] 29, 58, 116, 188, (230 psi with orifice (AO) 22, 32)
Pressure1) p [psig] 232 215 203 193 178

Temperature1) T [°F] 14/68 212 302 392 464
5
Pressure & temperature ratings – continued – Operating data
Equipment with sightglass cover:
Limiting conditions for UNA 45 with sightglass cover: PN 16: max. service temperature 240 °C at
12.3 bar service pressure
flange Class 150, screwed sockets NPT, socket-weld end, butt-weld end ASME
Class 150: max. service temperature 240 °C at
Pressure1) p [barg] 19.6 17.7 15.8 13.8 12.4 12.4 bar service pressure. If the pH value
Temperature1) T [°C] –29/20 100 150 200 240 is above 9.0 and the fluid temperature
exceeds 200 °C the glass will wear down
faster.
Max. admissible differential pressure [bar] 2, 4, 8, 13, (19,6 bar with orifice (AO) 22, 32) Equipment with measuring electrode
ΔPMX [psi] 29, 58, 116, 188, (284 psi with orifice (AO) 22, 32) NRG 16-19 or NRG 16-27,
Admissible service temperature Control unit DUPLEX: Saturated steam temperature plus 5 K PN 40/Class 300: max. service temperature 238 °C at
Pressure1) p [psig] 285 260 230 200 180 with Perbunan rolling ball:
Temperature1) T [°F] –20/100 200 300 400 465 max. service temperature 40 °C at ΔPMX
1) Resistance limits of body/cover to ASME B 16.5 16 bar.
Limiting conditions for UNA 46A: flange PN 40, screwed sockets G, butt-weld ends EN to the saturated steam temperature +5 K.
Pressure1) p [barg] 40.0 37.9 31.8 27.6 25.7 25
Temperature1) T [°C] –10/20 100 200 300 4002) 4502)

ΔPMX [psi] 29, 58, 116, 188, 320, 465
Pressure1) p [psig] 580 550 461 400 373 363

Temperature1) T [°F] 14/68 212 392 572 752 842
2) If the operating temperatures exceed 300 °C intercrystalline corrosion may occur. Do not subject the equipment to operating
temperatures higher than 300° C unless intercrystalline corrosion can be ruled out.
Limiting conditions for UNA 46A: flange Class 150

Pressure1) p [barg] 15.9 13.3 11.2 10.0 6.5 5.5
Temperature1) T [°C] –29/20 100 200 300 4002) 4252)
Max. admissible differential pressure [bar] 2, 4, 8, 13, (15,9 bar with orifice (AO) 22, 32)
Pressure1) p [psig] 230 195 160 140 95 80

Temperature1) T [°F] – 20/100 200 400 600 750 800
Limiting conditions for UNA 46A:

flange Class 300, screwed socket NPT, socket-weld end, butt-weld end ASME
Pressure1) p [barg] 41.4 34.8 29.2 26.1 24.3 23.9
Temperature1) T [°C] –29/20 100 200 300 4002) 4252)

ΔPMX [psi] 29, 58, 116, 188, 320, 465
Pressure1) p [psig] 600 510 420 370 355 345

Temperature1) T [°F] –20/100 200 400 600 750 800
6
Capacity Chart Capacity Chart
The chart shows the maximum capacities for hot condensate
for the various orifices. [lb/h] [kg/h]
The capacities are dependent on the differential pressure 15000 7000
(working pressure). 6000
2
The differential pressure is the difference between inlet and 5000 AO
10000 65-
outlet pressure and depends among other things on the 40-
4000 DN O4 AO
8
run of the condensate line. If the condensate downstream 8000 -A - 22
0-6
5
-65 13 - AO 32
of the trap is lifted, the differential pressure is reduced by 4 0 O AO
3000 DN N4 -A -65 -
approximately 1 bar for 7 m lift. 6000 D -65 40 -65
40 DN 40
The max. admissible differential pressure is a function of DN DN
the cross-sectional area of the orifice and the density of the 2000
4000
fluid to be discharged.
The graphs in the chart show the hot water flowrates that the 3000 4
steam traps UNA 45, UNA 46 and UNA 46A can discharge - AO
with virtually no banking up. 1000 2 -25 O
8
3
2000 AO 15 -A O1
The cold water capacities of steam traps with control unit - DN 5-2
5 -A 22
800 5 -25 N1 5-2
5
AO
SIMPLEX / DUPLEX are: Capacity multiplied by factor F. 1 -
DN
D
D N1 -25 O3
2
600 15 -A
DN 5-2
5
1
1000
500 DN
400
800
300
600
Durchfluss
200
Capacity
400
300
100
200 [bar]
0,1 0,2 0,3 0,4 0,6 0,8 1 2 3 4 5 6 8 10 20 32
[psi]
1,5 2 3 4 6 8 10 20 30 40 60 80 100 200 300 465
Differenzdruck
Differential pressure
Factor F = 1 1.1 1.18 1.2 1.3 1.4 1.48 1.53
The max. differential pressure Δ PMX of the equipment depends on the type of orifice (AO) used.
Diameter of bore [mm]
Orifice ΔPMX [bar]
DN 15-25 DN 40-65
2 2 8 15.0
4 4 6 12.5
8 8 4.8 10.0
13 13 4.1 8.5
22 22 3.5 7.0
32 32 3.0 6.5
7
Ball Float Steam Trap Spare Parts
3 27 4
UNA 45, UNA 46, UNA 46A 13 31
PN 40/Class 300
DN 15, 20, 25, 40, 50, 65 12
Inspection & Certification

Documentation regarding material tests and in-house
examination with test report to EN 10204 available at extra
cost. All inspection requirements have to be stated with the
enquiry or order. After supply of the equipment certification
cannot be established. Charges and extent of the above 1 Delivery quantity: 20 pcs.
mentioned test certificates as well as the different tests 16 32 2 560486: Material 1.4301
confirmed therein are listed in our Price List “Test and In-
560514: Material 1.4571
spection Charges for Standard Equipment”. For other tests 28 18 19 20 3 Comprises:
and inspections please consult us.
4 joint rings 3/8"
1 joint ring ¼"
Application of European Directives 1 body gasket
Pressure Equipment Directive 1 gasket for control unit
The equipment conforms to this directive and can be used
DN 15-25 DN 40-65
for the following media:
Cover for Cover for
UNA 45 Standard Sightglass Standard Sightglass
Item no. Designation Orifice mounting mounting
Fluids of group 2 cover cover cover cover
electrodes electrodes
UNA 46 and UNA 46A Stock code #
Fluids of group 1
Fluids of group 2 2 560656 560669
ATEX Directive Control unit 4 560657 560670
SIMPLEX, cpl. with 8 560658 560671
The equipment does not have its own potential ignition source
3, 4, 27 body gasket and
and is not subject to this directive. 13 560659 560672
gasket for control
When installed, static electricity may arise between the unit 22 560660 – 560673 –
equipment and the connected system. When used in po-
tentially explosive atmospheres, the plant manufacturer or 32 560661 – 560674 –
plant operator is responsible for discharging or preventing Control unit
possible static charge. SIMPLEX-P, cpl.
If it is possible for medium to escape, e.g. through actuating 3, 19, 27 with body gasket 16 560662 –
mechanisms or leaks in threaded joints, the plant manufacturer and gasket for
or plant operator must take this into consideration when control unit
dividing the area into zones. 2 560650 560663
Control unit 4 560651 560664
DUPLEX, cpl. with 8 560652 560665
3, 18,
body gasket and
27, 28 13 560653 560666
gasket for control
unit 22 560654 – 560667 –
32 560655 – 560668 –
Membrane regulator
3, 28 capsule 5N2, cpl. with all 560494 560687
body gasket
Hand vent valve,
12, 13 complete with all 560676 – 560676 560676 – 560676
gasket
Float-lifting lever,
12, 16 complete with all 560677 560678
gasket
3 Body gasket1) all 560493 560680
Joint ring for sealing

plug 3/8",
12 manual float-lifting all 5604862) or 5605142)
lever, hand-vent
valve or bypass1)
27 Gasket for control unit1) all 560681 560682

3, 12, 27 Gasket set3) all 560683 – 560684 –
Sightglass, incl.
Supply in accordance with our general terms of business. 31, 32 all – 560685 – 560480
gasket
GESTRA AG
Münchener Straße 77, 28215 Bremen, Germany
Telefon +49 421 3503-0, Telefax +49 421 3503-393
E-mail [email protected], Web www.gestra.de
819345-03/03-2017cm (808923-02) · GESTRA AG · Bremen · Printed in Germany
8
UNA 45
UNA 46
UNA 46A
Original Installation Instructions

819311-02
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 ......................................................................................................................................5
Typographic features of warning notes ....................................................................................................5
Formatting features for warnings of property damage ..............................................................................5
Description .........................................................................................................................................6
Scope of supply and equipment specification ..........................................................................................6
Task and function ..................................................................................................................................9
Storing and transporting the equipment.........................................................................................10
Storing the equipment .........................................................................................................................10
Transporting the equipment .................................................................................................................11
Mounting and connecting the equipment .......................................................................................11
Preparing installation ...........................................................................................................................11
Orientation of the equipment ................................................................................................................12
Connecting the equipment ...................................................................................................................13
Operation ..........................................................................................................................................16
After operation .................................................................................................................................17
Removing external dirt deposits ............................................................................................................18
Maintaining the equipment ...................................................................................................................18
Servicing the equipment and installing spare parts ................................................................................22
Troubleshooting ...............................................................................................................................30
Putting the equipment out of operation ..........................................................................................32
Removing harmful substances ..............................................................................................................32
Removing the equipment .....................................................................................................................32
Re-using equipment after storage .........................................................................................................33
Disposing of the equipment ..................................................................................................................34
Technical data ..................................................................................................................................35
Dimensions and weights ......................................................................................................................35
Pressure & temperature ratings ............................................................................................................42
Manufacturer's declaration .............................................................................................................47
Foreword Cross-reference
This installation & operating manual will help you  Listing
use the following types of equipment safely and  Sub-items in listings
efficiently for their intended purpose.
 Steps for action.
 UNA 45
 UNA 46 Here you will find additional useful
 UNA 46A information and tips serving to assist you
in using the equipment to its fullest
These steam traps will be called equipment in this potential.
document.
This installation & operating manual is intended for

anyone commissioning, using, operating, servicing, Safety
cleaning or disposing of this equipment and, in
particular, for professional after-sales service Use for the intended purpose
technicians, qualified personnel and authorised and
The following ball float steam traps are designed to
trained staff.
discharge condensate from steam systems:
All of these persons must read and understand the
 UNA 45
content of this installation & operating manual.
 UNA 46
Following the instructions given in this installation &
operating manual helps avoiding danger and  UNA 46A
increases the reliability and service life of the
Equipment type UNA 45 can also be used for
equipment. Please note that in addition to the
removing condensate from compressed air
instructions given in this installation & operating
systems.
manual you must also observe all locally applicable
rules and regulations concerning the prevention of Equipment type UNA 46 and UNA 46A can also be
accidents as well as approved safety guidelines for used for removing condensate from gases or gas
good professional practice. mixtures.
The equipment must only be used within the

Availability allowable pressure and temperature limits and only
if the chemical and corrosive influences on the
Keep this installation & operating manual together equipment are taken into account.
with the plant documentation for future reference.
Make sure that this installation & operating manual Do not expose the membrane regulator capsule of
is available to the operator. the DUPLEX control unit to superheat conditions
The installation & operating manual is part of the above 5 K.
equipment. Please hand over this installation & Correct use includes compliance with the
operating manual when selling the equipment or instructions given in this installation & operating
passing it on. manual, in particular obedience to all safety
instructions.
Formatting features in the Any other use of the equipment is considered to be

improper.
document
Note that the equipment is also used incorrectly if
Certain text elements of this installation & operating
the materials of the equipment are not suitable for
manual feature a specific typographic design. You
the fluid.
can easily distinguish the following text elements:
Standard text
3
Basic safety notes temperature ratings see name plate and the
section "Technical Data".
Risk of severe injuries
Risk of minor injuries
 The equipment is under pressure during
operation and may be hot. Before carrying out  Sharp edges on internals present the danger of
any work on the equipment make sure that the cuts to hands. Always wear industrial gloves
following requirements are met: when servicing the equipment.
 The pipes must be depressurized (0 bar).  If the support of the equipment during
installation is insufficient the equipment might
 The fluid must be completely removed from fall down, thereby causing bruises or injuries.
the pipes and the equipment. Make sure the equipment is safely held in place
 During work on the equipment the during installation and cannot fall down. Wear
installation must be switched off and protective safety footwear.
protected against unauthorised or
unintended activation.
Information on property damage
 The pipes and the equipment must have
cooled down to room temperature (approx.
or malfunctions
20 °C).  Malfunctions will occur if the equipment is
 If the equipment is used in contaminated areas installed in a wrong position or with the flow
there is a risk of severe injuries or death caused arrow pointing in the opposite direction of the
by harmful substances in or on the equipment. fluid flow. This may result in damage to the
Before working on the equipment make sure equipment or the installation. Make sure that
that it is completely decontaminated. Always the flow arrow on the equipment body matches
wear the protective clothing prescribed for the indicated direction of the fluid flow in the
contaminated areas when working on the pipe.
equipment.  If the material is unsuitable for the fluid,
 The equipment must only be used with fluids increased wear may occur and fluid may
that do not attack the material and the gaskets escape. Make sure that the material is suitable
and sealings of the equipment. Otherwise leaks for the fluid used in your installation.
may occur and hot or toxic fluid could escape.
 The equipment and its component parts must Qualification of personnel
only be mounted or removed by qualified A qualified person must be acquainted with and
personnel. A qualified person must be experienced in the following:
acquainted with and experienced in the  the pertinent on-site rules and regulations for
following: preventing fire and explosions as well as
 Making pipe connections. industrial safety regulations
 Selecting suitable lifting gear and  working on pressure equipment
understanding the rules for its safe use.  making pipe connections
 Working with dangerous (contaminated, hot  working with dangerous (hot or pressurized)
or pressurized) fluids. fluids
 If the admissible temperature and pressure  lifting and transporting loads
limits are exceeded the equipment may be
destroyed and hot or pressurized fluid may  observing all notes and instructions in this
escape. Make sure that the equipment is only installation & operating manual and the
operated within the admissible service range applicable documents
and limits.
For more information on limits and pressure &
4
Protective gear Typographic features of warning
The operator must ensure that anyone working on notes
the equipment must wear the required protective
clothing and safety gear stipulated for the site of
installation. The protective clothing must be suitable
DANGER
for the used media and must protect the wearer Notes with the heading DANGER warn
against safety and health hazards associated with a against imminent dangerous situations that
particular job to be carried out at the site of can lead to death or serious injuries.
installation. Protective clothing & equipment must
provide protection from potential hazards, in
particular from injuries to:
WARNING
 Head
 Eyes Notes with the heading WARNING warn
against possibly dangerous situations that
 Body could lead to death or serious injuries.
 Hand
 Feet
 Hearing CAUTION
Note that this list is not exhaustive. The operator Notes with the heading CAUTION warn
must establish personal protective equipment against dangerous situations that could
guidelines and specify any additional protective lead to minor or moderate injuries.
gear that is required if the worker is exposed to a
specific risk at the site of installation.
Formatting features for warnings
of property damage
Attention!
This information warns of a situation
leading to property damage.
5
Description
Scope of supply and equipment

specification
Scope of supply
Our equipment is delivered packed and ready for
assembly.
Equipment specification
Item Designation Item Designation

no. no.
1 Direction of flow arrow 6 Name plate
2 Body 7 Cover (shown here: standard cover)
3 Body gasket 8 Orifice
4 Control unit (shown here: control unit 9 Screws (4 pcs.)
SIMPLEX)
5 Float
6
Optional extras
The following items are available as optional extra:

no. no.
10 Strainer 14 Sightglass cover with integrated reflexion
11 Sealing plug water level indicator
12 Gasket 15 Drain with sealing plug
13 Hand-vent valve with socket spanner 16 Float-lifting lever with socket spanner
(socket spanner not shown) 17 Cover with connections for electrodes
The vent hole in the cover for the hand- NRG 16-19 or NRG 16-27
vent valve can also be used for
connecting a balance line.
7
The equipment can be fitted optionally with the The different equipment versions allow you to adjust
following control units: the flow direction of the equipment to the flow
pattern of your installation. The flow arrow must
correspond to the direction of the fluid flow. The
following positions of installation are possible:
 "v" for installation in vertical pipework with
downward flow
 "hl" for flow from right to left (when viewed from
the body end)
 "hr" for flow from left to right (when viewed from
the body end)
Item Designation
no.
18 Control unit DUPLEX with membrane
regulator capsule
19 Control unit SIMPLEX-P with Perbunan®
rolling ball
20 Control unit with externally adjustable
internal bypass
End connections
The equipment is available with the following end
connections:
 Flanges
 Screwed sockets
 Socket-weld ends
 Butt-weld ends via transition pieces
8
Name plate Application of European Directives
The following items are indicated on the name
Pressure Equipment Directive
plate:
The equipment conforms to this directive (see
 Manufacturer
"Manufacturer's Declaration" section) and can be
 Type designation used for the following media:
 Design UNA 45
 Nominal size  Fluids of group 2
 Pressure rating
UNA 46 and UNA 46A
 Design temperature
 Fluids of group 1
 Design pressure
 Max. service temperature
 Max. admissible differential pressure ATEX Directive
 CE marking The equipment does not have its own potential
 Date of manufacturing ignition source and is not subject to this directive
 Material number (see "Manufacturer's Declaration" section).
The following items are indicated on the equipment When installed, static electricity may arise between
body: the equipment and the connected system.
 Material When used in potentially explosive atmospheres,
 Batch code the plant manufacturer or plant operator is
responsible for discharging or preventing possible
 Direction of flow static charge.
The following items are indicated on the end
connections: If it is possible for medium to escape, e.g. through
actuating mechanisms or leaks in threaded joints,
 Flange size
the plant manufacturer or plant operator must take
 Flange face type (RJ number) this into consideration when dividing the area into
 Thread type zones.
The limiting conditions and pressure &

temperature ratings specified in this Task and function
installation manual are applicable for
standard equipment. Note that these Purpose
values may differ for modified or UNA 45, UNA 46 and UNA 46A is steam process
customized equipment. equipment designed for the effective removal of
All equipment specific values are indicated condensate from steam.
on the nameplate. Equipment type UNA 45 can also be used for
systems.
Equipment type UNA 46 and UNA 46A can also be
used for removing condensate from gases or gas
mixtures.
9
Function Storing and transporting the
A ball float opens the orifice as a function of the equipment
liquid level, thereby controlling the condensate
flowrate to be discharged. The max. discharge
capacity depends on the orifice size when the ball is Attention!
completely lifted off its seat and the orifice is fully
open. Equipment can be damaged if stored or
transported improperly.
Equipment with a control unit type SIMPLEX is
particularly suitable for cold condensates and  Close all openings with the sealing
superheated steam. plugs or covers supplied with the
Equipment fitted with control unit SIMPLEX-P is equipment or use similar sealing
operated and controlled by the float and the rolling covers.
ball. The Perbunan® rubber rolling ball ensures tight  Protect the equipment against
shut-off at the seat. Equipment with this type of moisture and corrosive atmospheres.
control unit is particularly suitable for cold
condensate and cold distillates.  Please contact the manufacturer if the
specified transport and/or storage
Equipment with control unit DUPLEX may also be
requirements cannot be met.
used for air venting the installation. The control unit
DUPLEX consists of a float operated rolling ball
valve mechanism and, in addition, a temperature
dependent air-venting facility. The air venting is
Storing the equipment
controlled by the membrane regulator. Equipment  Please observe the following items when storing
with this type of control unit is particularly suitable the equipment:
for saturated steam systems. Do not expose the
 Do not store the equipment for more than 12
membrane regulator capsule of the DUPLEX control
months.
unit to superheat conditions above 5 K.
 Use the supplied sealing plugs or other suitable
The optional float-lifting lever allows you to lift the
seal caps in order to seal off all openings of the
float manually.
equipment.
The optional hand-vent valve allows you to air vent
 Protect the sealing surfaces and contact areas
the pipe manually.
against mechanical damage.
By means of the externally adjustable internal
 Protect the equipment and all components
bypass it is possible to adjust a bypass passage
against hard shocks and impacts.
that flows past the control unit.
 Store the equipment only in closed rooms that
meet the following environmental conditions:
 Air humidity below 50 %, not condensing
 Indoor air: clean, salt-free and non-corrosive
 Temperature 5–40 °C.
 Make sure that all these requirements are

always met when storing the equipment.
 Please contact the manufacturer if you cannot
comply with the recommended storage
conditions.
10
Transporting the equipment Mounting and connecting the
equipment
CAUTION
Do not drop the equipment. If it falls down
Preparing installation
it may cause bruises and injuries.  Take the equipment out of the transport
packaging.
 To transport and mount the equipment
safely use suitable lifting gear.  Check the equipment for transport damage.
 Contact the manufacturer if you detect any kind
 Connect the noose strap of the lifting of shipping damage.
gear to the body.
When supplied by the factory, the connections may
 Provide sufficient support for the
be sealed off with sealing plugs.
equipment during transport and
installation.  Remove sealing plugs before mounting the
equipment.
 Wear protective safety footwear.
 Keep the sealing plugs and the packing for
Lightweight equipment may be transported and further use.
mounted without using any lifting gear.
To lift equipment the weight of which exceeds
approx. 25 kg, you need the help of a second
person or suitable lifting gear.
Your physical strength and on-site regulations and
conditions determine what weight can be lifted and
if support is required.
 Meet the requirements for storage also when
transporting the equipment.
 Prior to transport seal off connections with
sealing plugs.
If you do not have the sealing plugs
supplied with the equipment use
appropriate seal caps to seal off the
connections.
 For short distances (only a few metres) you can
transport the equipment unpacked.
 When transporting the equipment over larger
distances use the original packaging.
 If you do not have the original packaging use a
box that protects the equipment adequately
against corrosion and physical damage.
For a short period of time the equipment
may be transported even if the
temperature is below 0 °C, provided that
the equipment is completely empty and
dry.
11
Orientation of the equipment
DANGER The different equipment versions allow you to adjust
Personnel working on pipes are exposed to the flow direction of the equipment to the flow
safety risks and may suffer severe injuries, pattern of your installation. The following positions
poisoning or even loss of life. of installation are possible:
 with horizontal connections "hl" and "hr" for
 Make sure that no hot or hazardous installation in horizontal pipes
fluid is in the equipment or the pipes.
 with vertical connections "v" for installation in
 Make sure that the pipes upstream vertical pipework with downward flow
and downstream of the equipment are
depressurised.
 Make sure that the installation is
Attention!
switched off and protected against Malfunctions may occur if the control unit
unauthorised or unintended activation. is installed incorrectly.
 Make sure that the equipment and the  When installing the equipment make
pipes have cooled down to room sure that the name plate on the cover
temperatures. is on top and the float arm is free to
 Wear protective clothing that is move up and down.
suitable for the fluid and, if necessary,
To avoid malfunctions make sure the following
wear protective gear.
requirements are met when mounting the
For more information on suitable protective clothing equipment:
and safety gear refer to the safety data sheet of the  The flow arrow on the equipment body must
fluid in question. match the fluid flow direction.
 The name plate on the cover must point
 Drain pipes until they are empty.
upwards.
 Switch the installation off and protect it against
unauthorised or unintended re-activation.  Contact the manufacturer if you want to mount
the equipment in a different position of
installation.
 Detach the cover from the body as described on
page 19.
 Remove the control unit as described on
page 19.
 Turn the control unit by 90° or 180° into the
desired position of installation.
 Make sure that the float arm is free to move up
and down.
 Fix the control unit to the body as described on
page 20.
 Attach the cover to the body as described on
page 21.
12
Connecting the equipment
Attention!
DANGER Equipment will be damaged if the end
connections are undersized.
Incorrectly connected equipment can
cause fatal accidents or severe injuries.  Make sure that the connections are
strong and rigid enough to support the
 Make sure that only qualified skilled weight of the equipment and to
personnel connect the equipment to withstand the forces that occur during
pipes. operation.
 Make sure that the flow arrow on the
equipment body matches the direction Consider space required for servicing the
of flow in the pipe. equipment and/or exchanging components and
observe the necessary withdrawal distance to
Specialist personnel must be highly qualified and remove the cover. For more information on the
fully experienced in making pipe connections for the required withdrawal distances see section
respective type of end connection. "Dimensions and weights" on page 35.
 Make sure that the pipe system of the plant is

CAUTION clean.
 Make sure that the equipment is free from
Do not drop the equipment. If it falls down foreign matter.
it may cause bruises and injuries.  Mount the equipment in the desired installation
 To transport and mount the equipment position.
safely use suitable lifting gear.  Make sure that the pipes meet the following
requirements:
 Connect the noose strap of the lifting
gear to the body.  The layout of the pipelines must prevent the
 Provide sufficient support for the formation of water pockets.
equipment during transport and  The pipeline must have a gradient so that the
installation. condensate is free to fall towards the equipment
 Wear protective safety footwear.  The cross section of the air balance pipe must
be at least DN 8 (¼ ") .
Lightweight equipment may be transported and  If the equipment is fitted with control unit
mounted without using any lifting gear. SIMPLEX, an air balance pipe must be
To lift equipment the weight of which exceeds connected to the vent hole for the hand-vent
approx. 25 kg, you need the help of a second valve. The air balance pipe must have the
person or suitable lifting gear. following end connection dimensions:
Your physical strength and on-site regulations and  Standard cover and sightglass cover: G⅜ "
conditions determine what weight can be lifted and  Cover with electrode connections: G¼ "
 If one or more of the above mentioned
requirements cannot be met, please contact our
Technical Service or authorized agency in your
country.
 Connect the end connections of the equipment
properly to the pipes.
13
 If necessary, connect the air balance pipe to the
equipment as shown in the following drawing.
 Make sure that the equipment is safely mounted

and that all connections are made correctly.
14
Mounting the measuring electrode If you want to mount a measuring electrode NRG
If the equipment has a cover with electrode 16-27 with adapter (21) in the connection on top
connections you can attach one or two measuring proceed as follows:
electrodes of the following type:  Put the adapter gasket onto the adapter.
 To detect banking-up of condensate: NRG 16-  Screw the adapter (21) with gasket into the
19 or NRG 16-27 installed on top of the body connection on top.
(22)
 Tighten the adapter to a torque of 75 Nm.
 To detect loss of water seal: NRG16–19 or
The following steps are the same for both types of
NRG16–27 installed at the side of the body (24)
installation and connections:
To attach the NRG 16-27 on top of the  Use a suitable combination spanner to screw
body of equipment with DN 15 - 25 you the measuring electrode into the desired
need an adapter (21) with gasket. You can connection (22 or 24) on the body.
order this adapter with gasket (stock code
 Tighten the measuring electrode with a torque
# 556841) from the manufacturer.
of 75 Nm.
If the equipment is fitted with a standard cover you  Connect the body to the pipework as described
can fit the measuring electrode laterally. in the previous section.
The following tool is required for installation work:  Attach an air balance pipe to the connection
G¼ ” (23).
 Combination spanner A. F. 22, 24, 27 and 32
to DIN 3113 form B
 Torque spanner (US: wrench) 60-120 Nm to
DIN ISO 6789
Attention!
The measuring electrode might get
damaged if it is mounted incorrectly.
 Do not insulate the equipment after
installation of the measuring
electrode.
 Observe and follow all instructions
given in the installation & operating
manual for the measuring electrode.
To mount the measuring electrodes proceed as

follows:
 Apply heat resistant lubricant to the threads and
the terminal box side of the measuring
electrode.
The lubricant must have the same properties as
OKS®217.
15
Before mounting measuring electrodes The cast arrow on the body indicates the correct
please note: direction of rotation.
If a measuring electrode type NRG 16–27  To open the orifice turn the socket spanner from
is mounted on top of the body, only a the tip of the arrow towards the end of the
screwed union for a pipe with cross arrow.
section 8 mm will fit into the bore G¼”. If a  To close the orifice turn the socket spanner
screwed union for a pipe with cross from the end of the arrow towards the tip of the
section 10 mm were used, the hexagon arrow.
connection would press onto the
measuring electrode. Use the socket spanner (25) supplied with the
equipment to adjust the bypass flowrate of the
optional bypass.
Operation  To reduce the quantity turn the socket spanner

clockwise.
During operation you can undertake the following
work:  To increase the quantity turn the socket spanner
anticlockwise.
 Open and close the optional hand-vent valve
 Open and close the optional manual float-lifting
lever
 Adjust the optional bypass
To do this, use the socket spanner (stock code #

526110) supplied with the equipment.
The optional hand vent valve allows manual air

venting.
 To air vent the equipment turn the hand-vent

valve (viewed from top) anticlockwise.
 To close the hand-vent valve after air-venting
turn it clockwise.
 Fasten the hand-vent valve hand tight.
You can check the correct functioning of the
The optional float-lifting lever allows the float to be equipment during operation using the GESTRA
manually lifted irrespective of the liquid level. It can ultrasonic measuring unit VAPOPHONE® or
be used to purge any dirt away from the seat area TRAPTEST® (VKP 40 and VKP 40plus).
and out of the equipment by opening the orifice and
draining the liquid.  For more details refer to the installation &
operating manual of the ultrasonic measuring
unit.
16
After operation
DANGER
DANGER If the equipment is used in contaminated
areas there is a risk of severe injuries or
If fluid escapes personnel may suffer death caused by harmful substances in or
severe injuries, poisoning or even loss of on the equipment.
life.
 Only qualified personnel are allowed to
 After working on the equipment make perform work on contaminated
sure that all connections and valves equipment.
are tight.
 Always wear the protective clothing
 Make sure that the gaskets of the prescribed for contaminated areas
body are leakproof. when working on the equipment.
 Make sure that the equipment is
DANGER completely decontaminated before
carrying out any service work.
Personnel working on pipes are exposed to
 Follow the pertinent instructions for
safety risks and may suffer severe injuries,
handling the hazardous substances in
poisoning or even loss of life.
question.
 Make sure that no hot or hazardous
 Make sure that the pipes upstream
Attention!
and downstream of the equipment are Frost damage may occur when the
depressurised. installation is shut down.
 Make sure that the installation is  Drain the equipment if ambient
switched off and protected against temperatures below 0 °C (frost) are to
unauthorised or unintended activation. be expected.
 Make sure that the equipment and the
pipes have cooled down to room
temperatures.
 Wear protective clothing that is
For more information on suitable protective clothing

and safety gear refer to the safety data sheet of the
fluid in question.
17
 Provide a device that collects any fluid that may Maintaining the equipment
escape.
For work on the equipment you will need the
 Remove the sealing plug (15) at the bottom of following tools:
the body.
 Combination spanner form B to DIN 3113, sizes
 Allow all liquid to escape and wait until the body
is completely empty.  A. F. 17 mm
 To seal the drain hole screw in the sealing plug  A. F. 22 mm
and tighten it with a torque of 75 Nm.  A. F. 24 mm
 A. F. 32 mm
 Torque spanner to DIN ISO 6789
 up to 10 Nm
 10 – 60 Nm
 60 – 120 Nm
 120 – 300 Nm
 Allen key to DIN ISO 2936, sizes
 A. F. 4 mm
 A. F. 6 mm
 A. F. 8 mm
 Screwdriver 5.5/125 to DIN 5265
Malfunctions may occur if the equipment is

used with different types of condensate:
Removing external dirt deposits
The following condensates in particular
 To remove dirt deposits rinse the equipment cause problems:
with fresh water and wipe it with a clean, lint-
 very oily condensates
free cloth.
 condensates that resinify or become
 To remove any persistent residues use a
gummy
cleaning agent that is suitable for the material
and carefully wipe the equipment with a clean,  condensates that recrystallize
lint-free cloth.  condensates that contain solid matter.
In these cases check the equipment at
regular intervals for contamination and, if
necessary, remove dirt deposits.
To reduce contamination we recommend
installing a sedimentation vessel or a dirt
pocket arrangement upstream of the
equipment.
Normally you do not have to clean the internal parts

of the equipment.
To clean the equipment completely take off the
cover and remove the control unit.
The following drawings show equipment

type UNA 4 with standard cover.
18
Removing cover Removing control unit
Remove the measuring electrode(s) if  Detach the cover from the body as described on
mounted, before lifting off the cover. page 19.
 Use a combination spanner A. F. 32 to  Remove the socket-head cap screws (26).
DIN 3113, form B, to remove the  Detach the control unit (4) from the body (2).
measuring electrode.  Remove the gasket (27) for the control unit.
 Remove the four screws (9) in the body.  For the disposal of the gaskets observe the
 Lift the cover (7) off the body (2). pertinent on-site regulations concerning waste
disposal.
 Remove the body gasket (3).
 For the disposal of the body gasket observe the
pertinent on-site regulations concerning waste
disposal.
Cleaning the equipment

Check the equipment at regular intervals for
contamination. The intervals depend on the amount
of dirt in the system. The operator must determine
the maintenance intervals.
 Remove any parts that are dirty and cannot be

cleaned properly.
To clean the inside of the equipment proceed as

follows:

page 19.
page 19.
 To remove dirt deposits rinse the equipment
free cloth.
and carefully wipe the equipment with a clean,
lint-free cloth.
19
 Fix the control unit to the body as described on Fitting control unit in place
page 20.
 Attach the cover to the body as described on Attention!
page 21.
Malfunctions may occur if the control unit
Cleaning and checking the membrane is installed incorrectly.
regulator capsule  When installing the equipment make
To clean the membrane regulator capsule of sure that the name plate points
equipment with a DUPLEX control unit proceed as upwards and the float arm is free to
follows: move up and down.
 Detach the cover from the body as described on  Make sure that the flow arrow on the
page 19. equipment body matches the direction
 Remove the control unit as described on of flow in the pipe.
page 19.
 Check all removed parts for signs of damage.
 Remove the membrane regulator capsule as
described in section "Exchanging the membrane  Replace all worn or damaged parts.
regulator capsule" on page 28.  Clean all dirty parts.
 Clean the membrane regulator capsule with cold  Apply high-resistant lubricant to all threads,
clean water. bearing faces of screws, nuts and bolts.
 Use a depth gauge to check the dimension x of The lubricant must have the same properties as
the membrane regulator capsule as shown in OKS® 217.
the following drawing.
Attention!
Equipment may leak if the gasket is
damaged.
 Replace all gaskets that you loosen
The membrane regulator capsule is intact if during your work.
dimension x exceeds 4.0 mm.
 Use only new gaskets of the same
 Discard and replace defective membrane type.
regulator capsule with a new one.
 Mount the membrane regulator capsule as
described in section "Exchanging the membrane
regulator capsule" on page 28.
20
 Replace all gaskets with new ones of the same Mounting cover
type.
 Insert a new gasket (27) for the control unit into Attention!
the body (2).
 Turn the control unit (4) into the desired position Equipment may leak if the gasket is
of installation. damaged.
 Make sure that the control unit is not tilted or  It is therefore essential that you
skewed when fitted into the body. always insert a new gasket before re-
 Fix the control unit in place using the socket- attaching the cover.
head cap screws (26).  Make sure that the cover is not tilted
or skewed when refitted.
The tightening torque of the socket-head cap
screws depends on the equipment type.
 Clean the gasket surfaces of the cover and
 Equipment with DN 15 up to DN 25 requires a body.
torque of 4 Nm.
 Equipment with DN 40 up to DN 65 requires a bearing faces of the screws.
torque of 7 Nm.
 Fasten the socket-head cap screws with the OKS® 217.
specified tightening torque.
 Put a new body gasket (3) onto the body (2).
 Insert the four screws (9) into the bores of the
body.
 Refit the cover (7) onto the body such that the
name plate (6) points upwards.

page 21.
21
The tightening torque of the screws depends on the
equipment type.
 Equipment with DN 15 up to DN 25 requires a
torque of 35 Nm.
torque of 140 Nm.
 Tighten the four screws with the specified

torque.
 If necessary, mount the measuring electrode as
described on page 15.
Servicing the equipment and installing spare parts

You may exchange the following component parts
in case of wear or damage:
UNA 45, UNA 46 and UNA 46A with standard cover
22
Spare parts for equipment with standard cover
Item no. Designation Orifice DN 15–25 DN 40-65
Stock code #
3, 4, 27 Control unit SIMPLEX, cpl. with body 2 560656 560669
gasket and gasket for control unit 4 560657 560670
8 560658 560671
13 560659 560672
22 560660 560673
32 560661 560674
3, 19, 27 Control unit SIMPLEX-P, cpl. with body 16 560662 –
gasket and gasket for control unit
3, 18, 27, 28 Control unit DUPLEX, cpl. with body 2 560650 560663
8 560652 560665
13 560653 560666
22 560654 560667
32 560655 560668
3, 28 Membrane regulator capsule 5N2, cpl. all 560494 560687
with body gasket
12, 13 Hand vent valve, complete with gasket all 560676
12, 16 Float-lifting lever, complete with gasket all 560677 560678
3 Body gasket 1
all 560493 560680
12 Joint ring for sealing plug ⅜”, manual all 560486 or 5605142
2
float-lifting lever, hand-vent valve or

externally adjustable inner bypass1
27 Gasket for control unit1 all 560681 560682
3, 12, 27 Gasket set 3
all 560683 560684
1 Delivery quantity: 20 pcs.

2 560486: Material 1.4301, 560514: Material 1.4571
3 Comprises:
 4 joint rings ⅜‘‘
 1 joint ring ¼‘‘
 1 body gasket
 1 gasket for control unit
23
UNA 45 with cover for installing electrodes
24
Spare parts for UNA 45 with cover for installing electrodes
Stock code #
3.4, 27 Control unit SIMPLEX, cpl. with body 2 560656 560669
8 560658 560671
13 560659 560672
22 560660 560673
32 560661 560674
8 560652 560665
13 560653 560666
22 560654 560667
32 560655 560668
with body gasket
3 Body gasket1 all 560493 560680
12 Joint ring for sealing plug ⅜” or manual all 560486 or 5605142
2
float-lifting lever1
all 560683 560684

3 Comprises:
 1 body gasket
25
UNA 45 with sightglass cover
26
Spare parts for UNA 45 with sightglass cover
Stock code #
8 560658 560671
13 560659 560672
8 560652 560665
13 560653 560666
with body gasket
3 Body gasket 1
all 560493 560680
2
float-lifting lever or hand-vent valve1

31, 32 Reflexion water level gauge with 2 gaskets all 560685 560480

27
Exchanging the control unit
page 19.
page 19.
page 20.
page 21.
Exchanging the membrane regulator capsule

page 19.
In equipment with DN 15–DN 25 the cover

presses the membrane regulator capsule
onto the seat. You can therefore easily
detach the membrane regulator capsule
from the seat after removing the cover. Install the new membrane regulator capsule as
follows:
In equipment with DN 40 and DN 50 a
mounting clip is used to fix the membrane  Press the membrane regulator capsule onto the
regulator capsule in place. To exchange seat until it snaps into place.
the membrane regulator capsule first you  Slip the mounting clip over the membrane
have to remove the mounting clip. For this regulator capsule.
purpose you have to remove the control  Attach the cover to the body as described on
unit. Proceed as follows: page 21.
 Push the mounting clip (29) off the control unit
 Pull the membrane regulator capsule (28)
upwards and off the seat (2.).
28
Replacing the sightglass of the sightglass
cover Attention!
 Remove the socket-head cap screws (34).
 Detach the flange (33) from the sightglass cover damaged.
(14).
 Remove the outer gasket (32).  Replace all gaskets that you loosen
during your work.
 Remove the sightglass (31).
 Remove the inner gasket (32).  Use only new gaskets of the same
type.
 For the disposal of the gaskets observe the
pertinent on-site regulations concerning waste  Apply heat resistant lubricant to the threads and
disposal. bearing faces of the socket-head cap screws.
OKS® 217.
 Insert a new gasket in the sightglass cover.
 Insert a new sightglass.
 Put a new gasket on the sightglass.
 Screw the socket-head cap screws into the
bores of the flange.
 Tighten the socket-head cap screws alternately
and in several steps with a torque of 12 Nm.
29
Troubleshooting
Problem Cause Remedy
The equipment is cold or only The inlet or outlet shut-off valves Fully open the shut-off valves.
warm to the touch. are closed.
Insufficient flowrate.
Insufficient thermal output of
the user.
The equipment is cold or only The inlet, outlet or internals are If fitted, operate the float-lifting lever.
warm to the touch. dirty. Clean the pipes.
Insufficient flowrate. Clean the equipment.
the user.
Insufficient flowrate. The equipment is undersized. Install equipment with larger flowrate
Insufficient thermal output of capacity.
the user.
Insufficient flowrate. The differential pressure is too Increase the steam pressure.
Insufficient thermal output of small. Lower the pressure in the condensate
the user. lines.
Install equipment with larger flowrate
capacity.
Use a different equipment type.
Insufficient flowrate. The line leading to the equipment Lay the condensate line with a gradient
Insufficient thermal output of does not have a gradient. so that the condensate is free to fall
the user. towards the equipment.
Change the orientation of the pipeline.
Insufficient flowrate. Insufficient deaeration. Connect an additional air vent in
Insufficient thermal output of accordance with the instructions given by
the user. the manufacturer.
Contact the manufacturer to find out
which trap type is the most suitable for
your application.
Insufficient flowrate You did not remove the sealing Remove the equipment.
plugs from the connections. Remove the sealing plugs.
Mount the equipment.
The equipment is blowing off Dirt deposits, sediments or If fitted, operate the float-lifting lever.
live steam. foreign particles have Clean the equipment.
accumulated in the equipment.
If necessary, replace internal parts or the
whole equipment.
30
The equipment is blowing off The control unit is damaged or Replace the control unit.
live steam. worn. Replace the equipment with a new one.
The equipment is blowing off The bypass is open. Close the bypass.
live steam.
Fluid escapes (equipment is The connections are not tight. Provide the connections with leakproof
leaking). seals.
Fluid escapes (equipment is A gasket is damaged. Check the condition of the gaskets.
leaking). Replace any defective gasket.
Fluid escapes (equipment is The body has been damaged by Check the resistance of the material for
leaking). corrosion or erosion. the fluid used.
Use only equipment made of material
that is suitable for the fluid used.
Fluid escapes (equipment is The equipment is damaged. Check the condition of the equipment.
leaking). Replace the equipment if it is damaged.
Fluid escapes (equipment is The equipment has been Replace the equipment with a new one.
leaking). damaged by frost. When shutting down the installation
make sure that all lines and the
equipment are completely drained.
leaking). damaged by waterhammer. Take appropriate measures to protect the
equipment against waterhammer, e. g.
by installing suitable non-return valves.
The stuffing box is leaking. The stuffing box packing has not Tighten the stuffing-box packing hand
been tightened enough. tight. Make sure that the stuffing box
does not impair the movement of the
internals. The stuffing box must not leak.
The stuffing-box packing is Replace the stuffing-box packing.
damaged.
 If faults occur that are not listed above or cannot
be corrected, please contact our Technical
Service or authorized agency in your country.
31
Putting the equipment out of  Remove all residues from the equipment.
operation  For the disposal of all residues observe the
pertinent legal regulations concerning waste
disposal.
Removing harmful substances
Removing the equipment
DANGER
If the equipment is used in contaminated DANGER
death caused by harmful substances in or Personnel working on pipes are exposed to
on the equipment. safety risks and may suffer severe injuries,
perform work on contaminated  Make sure that no hot or hazardous
equipment. fluid is in the equipment or the pipes.
 Always wear the protective clothing  Make sure that the pipes upstream
prescribed for contaminated areas and downstream of the equipment are
when working on the equipment. depressurised.
 Make sure that the equipment is  Make sure that the installation is
completely decontaminated before switched off and protected against
carrying out any service work. unauthorised or unintended activation.
 Follow the pertinent instructions for  Make sure that the equipment and the
handling the hazardous substances in pipes have cooled down to room
question. temperatures.
Qualified personnel must have extensive experience  Wear protective clothing that is
with and a working knowledge of: suitable for the fluid and, if necessary,
 pertinent rules and regulations concerning wear protective gear.
handling hazardous substances
 special regulations for handling the hazardous and safety gear refer to the safety data sheet of the
substances encountered on site fluid in question.
 using the required personal protective
equipment (PPE) and clothing
CAUTION
Caution Risk of injuries if the equipment falls down.
Environmental damage may be caused by  When removing the equipment make
poisonous fluid residues. sure the it is safely held in place and
cannot fall down.
 Before disposing of the equipment
make sure that it is clean and free of Suitable measures are for instance:
fluid residues.
 Equipment that is not too heavy may be
 For the disposal of all materials supported by a second person.
observe the pertinent legal regulations  For heavy equipment use suitable lifting
concerning waste disposal. equipment of sufficient strength.
32
 Detach the end connections of the equipment
from the pipes.
 Put the equipment onto a suitable base.
 Store the equipment as described in section
"Storing the equipment" from page 10
onwards.
Re-using equipment after storage

Observe the following instructions if you want to
remove the equipment and use it again somewhere
else:
 Make sure that the equipment is free of any
fluid residues.
 Make sure that all connections are in good
condition and leak-free.
 If necessary re-work welded connections in
order to ensure that they are in good working
condition.
 Use the equipment only for its intended purpose

and the service conditions for which it was
specified.
33
Disposing of the equipment
Caution
Environmental damage may be caused by
poisonous fluid residues.
make sure that it is clean and free of
fluid residues.
 For the disposal of all materials
observe the pertinent legal regulations
concerning waste disposal.
The equipment is made from the following

materials:
Component part Type EN ASTM

Body UNA 45, UNA 46 1.0460 A105
UNA 46A 1.4404 A182-F316L
Cover UNA 45 sightglass 5.3103 A3951
cover / cover for
installing electrodes
UNA 46 1.0619 SA216-WCB
UNA 46A 1.4408 A351-CF8M
Body gasket, control all Graphite CrNi
unit gasket
Other components all Stainless steel
1 Physical and chemical properties comply with EN grade. ASTM nearest equivalent grade is
stated for guidance only.
34
Technical data

The drawing shows equipment with standard cover
and flanged connection for vertical downward flow.
35
Nominal size DN 15 DN 20 DN 25 DN 40 DN 50 DN 65
(½”) (¾”) (1”) (1½”) (2”) (2½”)
Overall length L [mm 150 (5.9) 160 (6.3) 230 (9.1) 290 (11.4)
(in)]
B [mm (in)]
Standard cover 171 (6.7) 287 (11.3)
Cover for mounting 186 (7.3) 306 (12.0)
electrodes
H1 [mm (in)] 60 (2.4) 107 (4.2)
H2 [mm (in)] 90 (3.5) 1
151 (5.9)1
Total height H [mm (in)] 150 (5.9) 1
258 (10.2)1
Width L1 [mm (in)] 110 (4.3)2 170 (6.7)2
X [mm (in)] 13 (0.5)
Weight [kg]
Standard cover 6.8 7.3 7.8 24.8 26.2 28.6
Cover for mounting 8.5 9.0 9.5 28.0 29.4 31.8
electrodes
Weight [lb]
Standard cover 15.0 16.1 17.2 54.7 57.8 63.1
electrodes
1 If equipped with hand-vent valve add 25 mm (1 in).

2 If equipped with hand-vent valve or bypass add 35 mm (1.4 in).
36
(½”) (¾”) (1”) (1½”) (2”) (2½”)
Overall length L [mm 150 (5.9) 160 (6.3) 241 (9.5) 267 (10.5) 292 (11.5)
(in)]
B [mm (in)]
Standard cover 171 (6.7) 287 (11.3)
electrodes
H1 [mm (in)] 60 (2.4) 107 (4.2)
H2 [mm (in)] 90 (3.5) 1
151 (5.9)1
258 (10.2)1
Width L1 [mm (in)] 110 (4.3)2 170 (6.7)2
X [mm (in)] 13 (0.5)
Weight Class 150
Weight [kg]
Standard cover 6.2 6.6 7.2 23.8 25.9 29.4
electrodes
Weight [lb]
Standard cover 13.7 14.6 15.9 52.5 57.1 64.8
electrodes
Weight Class 300
Weight [kg]
Standard cover 6.6 7.4 8.2 26.0 27.5 31.1
electrodes
Weight [lb]
Standard cover 14.6 16.3 18.1 57.3 60.6 68.6
electrodes

37
(½”) (¾”) (1”) (1½”) (2”) (2½”)
(in)] (Socket-weld end) (Butt-weld end via
transition pieces EN,
ASME)
B [mm (in)]
Standard cover 171 (6.7) 287 (11.3)
electrodes
H1 [mm (in)] 60 (2.4) 107 (4.2)
H2 [mm (in)] 90 (3.5) 1
151 (5.9)1
258 (10.2)1
Width L1 [mm (in)] 110 (4.3)2 170 (6.7)2
X [mm (in)] 13 (0.5)
Weight [kg]
Standard cover 5.3 5.2 21.2 21.9 24.6
Cover for mounting 7.0 6.9 24.4 25.1 27.8
electrodes
Weight [lb]
Standard cover 11.7 11.5 46.7 48.3 54.5
electrodes

38
Nominal size DN 15 DN 20 DN 25 DN 40 DN 50
(½”) (¾”) (1”) (1½”) (2”)
B [mm (in)]
Standard cover 171 (6.7) 287 (11.3)
electrodes
H1 [mm (in)] 60 (2.4) 107 (4.2)
H2 [mm (in)] 90 (3.5) 1
151 (5.9)1
Total height H [mm (in)] 150 (5.9)1 258 (10.2)1
Width L1 [mm (in)] 110 (4.3) 2
170 (6.7)2
X [mm (in)] 13 (0.5)
Weight [kg]
Standard cover 5.3 5.2 5.1 21.2 20.9
electrodes
Weight [lb]
Standard cover 11.7 11.5 11.2 46.7 46.1
electrodes

39
(½”) (¾”) (1”) (1½”) (2”) (2½”)
(in)]
B [mm (in)]
Standard cover 171 (6.7) 287 (11.3)
electrodes
H1 [mm (in)] 60 (2.4) 107 (4.2)
H2 [mm (in)] 90 (3.5) 1
151 (5.9)1
258 (10.2)1
Width L1 [mm (in)] 110 (4.3)2 170 (6.7)2
X [mm (in)] 13 (0.5)
Weight [kg]
Standard cover 5.6 5.7 21.3 21.6 22.5
electrodes
Weight [lb]
Standard cover 12.3 12.6 47.0 47.6 49.6
electrodes

40
To remove the cover a withdrawal space S of

240 mm is required.
If the supplied socket spanner is attached to the
equipment an additional clearance of 100 mm is
required.
41
Pressure & temperature ratings
The values indicated in the following tables apply to
standard equipment.
Note that the type of end connection used may
restrict the use of the equipment to below the
pressure/temperature limits quoted.
All equipment specific values are indicated on the
nameplate.
Limiting conditions for UNA 45 and UNA 46: Flange PN 40, screwed sockets G
Pressure1 p [barg] 40 37.1 33.3 27.6 25.7 13.12
Temperature1 T [°C] –10/20 100 200 300 350 4502

∆PMX [psi] 29, 58, 116, 188, 320, 465
Pressure1 p [psig] 580 538 483 400 373 1902

Temperature T 1
[°F] 14/68 212 392 572 662 8422
1 Limit values for body/cover to EN 1092-1

2 Not for UNA 45
Pressure1 p [barg] 19.6 17.7 13.8 10.2 8.6 5.52
Temperature T 1
[°C] -29/20 100 200 300 345 4252
Max. admissible differential pressure [bar] 2, 4, 8, 13 (19.6 bar with orifice (AO) 22, 32)
∆PMX [psi] 29, 58, 116, 188 (284 psi with orifice (AO) 22, 32)
Pressure1 p [psig] 285 260 200 140 125 802

Temperature1 T [°F] -20/100 200 400 600 650 8002
1 Limit values for body/cover to ASME B 16.5

2 Not for UNA 45
42
Flange Class 300, screwed sockets NPT, socket-weld end, butt-weld end
Pressure1 p [barg] 51.1 46.6 43.8 39.8 37.8 28.82
Temperature T 1
[°C] -29/20 100 200 300 345 4252

∆PMX [psi] 29, 58, 116, 188, 320, 465
Pressure1 p [psig] 740 680 635 570 550 4102

Temperature1 T [°F] -20/100 200 400 600 650 8002

2 Not for UNA 45
Limiting conditions for UNA 45 with sightglass cover, flange PN 16, screwed sockets G
Pressure1 p [barg] 16.0 14.8 14.0 13.3 12.3
Temperature1 T [°C] -10/20 100 150 200 240
∆PMX [psi] 29, 58, 116, 188, (230 psi with orifice (AO) 22, 32)
Pressure1 p [psig] 232 215 203 193 178

Temperature1 T [°F] 14/68 212 302 392 464
43
Limiting conditions for UNA 45 with sightglass cover,
flange Class 150, screwed sockets NPT, socket-weld end, butt-weld end
Pressure1 p [barg] 19.6 17.7 15.8 13.8 12.4
Temperature T 1
[°C] -29/20 100 150 200 240
Max. admissible differential pressure [bar] 2, 4, 8, 13, (19.6 bar with orifice (AO) 22, 32)
Pressure1 p [psig] 285 260 230 200 180

Temperature1 T [°F] -20/100 200 300 400 465
Limiting conditions for UNA 46A, flange PN 40, screwed sockets G

Pressure1 p [barg] 40.0 37.9 31.8 27.6 25.7 25
Temperature T 1
[°C] -10/20 100 200 300 400 450
Max. admissible differential [bar] 2, 4, 8, 13, 22, 32

pressure ∆PMX [psi] 29, 58, 116, 188, 320, 465
Admissible service Control unit DUPLEX: Saturated steam temperature plus 5 K
temperature
Pressure1 p [psig] 580 550 461 400 373 363

Temperature1 T [°F] 14/68 212 392 572 752 842
44
Limiting conditions for UNA 46A, flange Class 150
Pressure1 p [barg] 15.9 13.3 11.2 10.0 6.5 5.5
Temperature1 T [°C] -29/20 100 200 300 400 425
Max. admissible differential [bar] 2, 4, 8, 13, (15.9 bar with orifice (AO) 22, 32)
pressure ∆PMX [psi] 29, 58, 116, 188 (230 psi with orifice (AO) 22, 32)
temperature
Pressure1 p [psig] 230 195 160 140 95 80

Temperature1 T [°F] -20/100 200 400 600 750 800
Limiting conditions for UNA 46A,

flange Class 300,, screwed socket NPT, socket-weld end, butt-weld end
Pressure1 p [barg] 41.4 34.8 29.2 26.1 24.3 23.9
Temperature T 1
[°C] -29/20 100 200 300 400 425

pressure ∆PMX [psi] 29, 58, 116, 188, 320, 465
temperature
Pressure1 p [psig] 600 510 420 370 355 345

Temperature1 T [°F] -20/100 200 400 600 750 800
45
Operating data
PN16: max. service temperature 240 °C at
12.4 bar service pressure. If the pH value is above
9.0 and the fluid temperature exceeds 200 °C the
glass will wear down faster.
Equipment with measuring electrode NRG 16–19 or
NRG 16–27, PN40/Class300:
max. service temperature 238 °C at 32 bar service
pressure
Equipment with control unit SIMPLEX-P with
Perbunan rolling ball: max. service temperature
40 °C at ∆PMX 16 bar.
Equipment with control unit DUPLEX: The

max.service temperature corresponds to the
saturated steam temperature +5 K.
According to the Body of Regulations AD 2000
300 °C is the limit temperature for resistance to
intercrystalline corrosion occurring in UNA 46A
made from material 1.4408.
The max. differential pressure Δ PMX of the
equipment depends on the type of orifice (AO) used.

Orifice ΔPMX Diameter of bore [mm]

[bar] DN 15–25 DN 40-65
2 2 8 15.0
4 4 6 12.5
8 8 4.8 10.0
13 13 4.1 8.5
22 22 3.5 7.0
32 32 3.0 6.5
46
Manufacturer's declaration
For more information on the Conformity
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
Telefon +49 421 3503-0
Telefax +49 421 3503-393
E-Mail [email protected]
Web www.gestra.de
This declaration is no longer valid if modifications

are made to the equipment without consultation
with us.
47
Agencies all over the world: www.gestra.de
GESTRA AG
28215 Bremen
Germany
Telefon +49 421 3503-0
Telefax +49 421 3503-393
Web www.gestra.de
819311-02/07-2016 kx_mp (808915-02) © GESTRA AG Bremen Printed in Germany
48
9. Sicherheitsventil
9. Safety Valve

Commission-N°:
7001021687
Factory-N°:
4020004 Project:
TIMOR 1
Drawing-N°:
BB2285A
Baujahr: Pos.-Nr.:
Datenblatt und Betriebsanleitung

Datasheet and Operating Instruction
Inlet: 1/2" PN 250 - male thread
safety valve
10 11LCA10AA310 1 LESER 4373.2604 Outlet: 1/2" PN 160 female Body 1.4401 / 1.4404 --
set pressure: 27 bar g
thread
Commission-No.:
Customer:
Stück/Benennung: 1 Stk. Leckdampfkondensatormodul Bestell-Nr.: 7001021687

Quantity/discription: 1 pc. Gland Steam Condenser Modul Order-No.:
Factory-No.:
4020004 TIMOR 1
Project:
Drawing-No.:
67-3265 BB285A
Project-No.:
Baujahr: Pos.-Nr.:
2021 --
Pos.-No.:
Pos. 10
11LCA10AA310
Type
437
Sicherheitsventile
Metrische Einheiten
Fakten
The-Safety-Valve.com
LWN 461.01-D
Type 437
Ausführungen
Type 437
40 Kappe H2
18 Druckschraube
mit Buchse Axialnadellager 69
19 Gegenmutter
16 Federteller
12 Spindel
54 Feder
2 Austrittsgehäuse
17 Federteller
57 Schwerspannhülse
61 Kugel
7 Teller
1 Eintrittskörper
Konventionelle Ausführung Long version

Gewindeanschluss Gewindeanschluss
Austrittsflansch 2.4
Austrittsadapter 2.1
Eintrittsflansch 48
Konventionelle Ausführung
Flanschanschluss
01/02 LWN 481.01-D

Type 437
Ausführungen und Werkstoffe
Type 437
Werkstoffe
Pos. Benennung Ausführungen Type 4373 Type 4374
1.4104 1.4404
Gewindeanschluss
SA 479 430 SA 479 316L
1.4404 1.4404
1 Eintrittskörper Flanschanschluss
SA 479 316L SA 479 316L
1.4404 stellitiert 1.4404 stellitiert
Long version
SA 479 316L stellitiert SA 479 316L stellitiert
1.4104 1.4404
2 Austrittsgehäuse
SA 479 430 SA 479 316L
1.4404 1.4404
2.1 Austrittsadapter Flanschanschluss
316L 316L
1.4404 1.4404
2.4 Austrittsflansch Flanschanschluss
316L 316L
1.4122 1.4404
Edelstahl gehärtet SA 316L
7 Teller
Long version
316L stellitiert 316L stellitiert
1.4021 1.4404
12 Spindel
420 316L
1.4104 1.4404
16/17 Federteller
Chromstahl 316L
Druckschraube 1.4104 / PTFE 1.4104 / PTFE
18
mit Buchse Chromstahl / PTFE 316L / PTFE
1.0718 1.4404
19 Gegenmutter
Stahl 316L
1.0718 1.4404
40 Kappe H2
Stahl 316L
1.4404 1.4404
48 Eintrittsflansch Flanschverbindung
316L 316L
1.4310 1.4310
54 Feder
Edelstahl Edelstahl
1.4310 1.4310
Edelstahl Edelstahl
1.3541 1.4401
61 Kugel
Edelstahl gehärtet 316
1.4404 1.4404
69 Axialnadellager Long version
316L 316L
Bitte beachten:
– LESER behält sich Änderungen vor.

– LESER kann, ohne vorherige Benachrichtigung, höherwertige Werkstoffe einsetzen.
– Jedes Bauteil kann entsprechend der Kundenspezifikation in einem anderen Werkstoff ausgeführt werden.
LWN 481.01-D 01/03

Type 437
How to order – Artikel-Nummern
Type 437
Artikel-Nummern
Engster Strömungsdurchmesser
10
d0 [mm]
Engster Strömungsquerschnitt
78,5
A0 [mm2]
0,394
d0 [inch]
0,122
A0 [inch2]
Werkstoff Eintrittskörper: 1.4104 (430)
H2 Art.-Nr. 4373. 2602

H3 Art.-Nr. 4373.
2603
pmax = 10 barg
H4 Art.-Nr. 4373. 2604
p [barg] D/G/F 0,1 – 93
p [psig] D/G/F 1,5 – 1349
Werkstoff Eintrittskörper: 1.4404 (316L)
H2 Art.-Nr. 4374. 3142
H4 Art.-Nr. 4374. 3144

p [barg] D/G/F 0,1 – 68
p [psig] D/G/F 1,5 – 986
Artikel-Nummern
Long version
6 6 10
d0 [mm]
28,3 28,3 78,5
A0 [mm2]
0,236 0,236 0,394
d0 [inch]
0,044 0,044 0,122
A0 [inch2]
H2 Art.-Nr. 4373. 2622 – 2612
H4 Art.-Nr. 4373. 2624 – 2614

p [barg] D/G/F 180 – 365 – 93 –180
p [psig] D/G/F 2611 – 5294 – 1349 – 2611
H2 Art.-Nr. 4374. 3122 3132 3153
H4 Art.-Nr. 4374. 3124 3134 3154

p [barg] D/G 180 – 365 F 180 – 3801) D/G/F 68 –180
p [psig] D/G 2611 – 4786 F 2611 – 5511 D/G/F 986 – 2611
1) Zurzeitkeine TÜV-Bauteilprüfung, einsetzbar für thermische Expansion.

„Long version“ nur bei Ansprechdrücken die Höher der konventionelle Ausführung liegen.
Für die Auswahl der Eintrittskörper und Austrittsgehäuse siehe Seite 04/04 – 04/05.
LWN 481.01-D 01/07

Type 437
Abmessungen und Gewichte – Metrische Einheiten
Gewindeanschlüsse
Type 437

1/ " 3/ " 1/ 3/ 1/ " 3/ "
Größe Austrittsgehäuse 2 4 1" 2" 4" 1" 2 4 1"
Engster Strömungsdurchmesser d0
10 10 10 6 6 6 10 10 10
[mm]
Engster Strömungsquerschnitt A0
78,5 78,5 78,5 28,3 28,3 28,3 78,5 78,5 78,5
[mm2]
Gewicht [kg] 1,2 1,6 1,6 1,4 2,1 2,1 1,4 2,1 2,1
Benötigter Einbaudurchmesser [mm] 65 80 80 65 80 80 65 80 80
Innengewinde Eintritt
DIN ISO 228-1 G Eintritt a 45 55 55 45 55 55 45 55 55
Schenkellänge [mm] Austritt b 30 37 37 30 37 37 30 37 37
Bauhöhe [mm] H max. 210 220 220 230 240 240 230 240 240
ISO 7-1/BS 21 Rc Eintritt a 45 55 55 45 55 55 45 55 55
Bauhöhe [mm] H max. 210 220 220 230 240 240 230 240 240
ANSI/ASME B1.20.1 NPT Eintritt a 45 55 55 45 55 55 45 55 55
Bauhöhe [mm] H max. 210 220 220 230 240 240 230 240 240
Außengewinde Eintritt
ISO 7-1/BS 21 R Eintritt a 31 31 34 31 31 34 31 31 34
Bauhöhe Außengewinde Eintritt

Eintrittsgewinde Größe 3/ 1/ " 3/ " 3/ 1/ 3/ "
8" 2 4 1" 8" 2" 4 1"
DIN ISO 228-1 [mm] G H max. 210 212 214 216 230 232 234 236
ISO 7-1/BS 21 [mm] R H max. – 215 216 219 – 235 236 239
ASME B1.20.1 [mm] NPT H max. – 218 218 223 – 238 238 243
Einschraublänge und Zapfenlänge „c“

Eintrittsgewinde Größe 3/ 1/ " 3/
8" 2 4" 1"
DIN ISO 228-1 [mm] G 12 14 16 18
ISO 7-1/BS 21 [mm] R – 19 20 23
ASME B1.20.1 [mm] NPT – 22 22 27
benötigter Einbaudurchmesser
Konventionelle Ausführung Konventionelle Ausführung Long version

Innengewinde Außengewinde Außengewinde
01/08 LWN 481.01-D
Type 437
Flanschanschlüsse
Type 437
[mm] 6 10 6 10
[mm2] 28,3 78,5 28,3 78,5
DIN ISO 1092-1 (Erhältliche Flanschgrößen siehe Seite 04/05)

Flanschdruckstufe PN 40
Schenkellänge [mm] Eintritt a 100 100 100 100
Austritt b 100 100 100 100
Bauhöhe [mm] H max. 263 263 284 284
Flanschdruckstufe ≥ PN 160
Austritt b 100 100 100 100
Bauhöhe [mm] H max. 266 266 287 287
ASME B 16.5 (Erhältliche Flanschgrößen siehe Seite 04/05)
Flanschdruckstufe Class 150
Austritt b 100 100 100 100
Bauhöhe [mm] H max. 263 263 284 284
Flanschdruckstufe Class ≥ 300
Austritt b 100 100 100 100
Bauhöhe [mm] H max. 266 266 287 287
Gewicht
Für die Berechnung des Gesamtgewichtes verwenden Sie bitte folgende Formel: mT = mN + mF(Eintritt) + mF(Austritt)
Nettogewicht [kg]
(ohne Eintritts- und Austrittsflansch) mN
2,4 2,4 2,8 2,8
Flanschmaße und Verfügbarkeit

DIN ISO 1092-1 / Flanschdruckstufe PN ASME B16.5 / Flanschdruckstufe
Größe 40 160 250 320 400 Größe 150 300 600 900 1500 2500
DN 15 NPS 1/2"
Flanschblattdicke [mm] s 18 22 26 26 30 14 18 26 30,2
Gewicht Losflansch [kg] mF 0,8 1,2 2,5 2,5 3,6 0,6 0,9 2,1 3
Eintrittsseitig erhältlich ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓
Austrittsseitig erhältlich ✓ ✓ ✓ ✓ ✓ ✓
DN 20 NPS 3/4"
Flanschblattdicke [mm] s 20 22 15 18 25,4 32
Gewicht Losflansch [kg] mF 1,1 1,3 0,8 1,4 2,3 3,5
Eintrittsseitig erhältlich ✓ ✓ ✓ ✓ ✓ ✓
Austrittsseitig erhältlich ✓ ✓ ✓ ✓ ✓
DN 25 NPS 1"
Flanschblattdicke [mm] s 22 26 30 36 40 17 21,5 32,5 40
Gewicht Losflansch [kg] mF 1,3 2,6 3,5 5 7,5 1 2,1 4,1 5,1
Austrittsseitig erhältlich ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓
a
s s
s
s
LWN 481.01-D 01/09

Type 437
Druck- / Temperatur-Einsatzbereiche
Type 437
Metrische Einheiten
6 10
d0 [mm]
28,3 78,5
A0 [mm2]
Gehäusewerkstoff: 1.4104 (430)
Eintrittskörper 3/ 1/ 3/ 3/ " 1/ " 3/
Anschlussgröße 8" 2" 4" 1" 8 2 4" 1"
Druckstufe PN 400 PN 250
Austrittsgehäuse Druckstufe PN 160 PN 160
Minimaler
p [barg] D/G/F 180 [nur D/G] 0,1
Ansprechdruck
Maximaler 10 [nur H3]
p [barg] D/G/F 365 [nur D/G]
Ansprechdruck 180
Temperatur min [°C ] -10 -10
nach DIN EN max [°C ] +220 +220
nach ASME max [°C ] +220 +220
Gehäusewerkstoff: 1.4404 (316L)
Anschlussgröße 8" 2" 4" 1" 8 2 4" 1"
Minimaler
Ansprechdruck
Ansprechdruck 180
US Einheiten
0,236 0,394
d0 [mm]
0,044 0,122
A0 [mm2]
Eintrittskörper 3/ 1/ 3/ " 3/ 1/ " 3/
Anschlussgröße 8" 2" 4 1" 8" 2 4" 1"
Minimaler
p [barg] D/G/F 2610 1,
Ansprechdruck
p [barg] D/G/F 5294
Ansprechdruck 2610
Temperatur min [°F ] +14 +14
nach DIN EN max [°F ] +428 +428
Temperatur min [°F ] -20 -20
nach ASME max [°F ] +428 +428
Anschlussgröße 8" 2" 4 1" 8" 2 4" 1"
Minimaler
p [barg] D/G/F 2610 1,5
Ansprechdruck
p [barg] D/G/F 5294
Ansprechdruck 2610
01/12 LWN 481.01-D

Type 437
Zusatzausrüstungen
Type 437
Außengewinde Innengewinde Flanschanschluss
Stellitierte Dichtfläche Teller mit eingesetzter Dichtplatte

J25: Teller stellitiert J44: PTFE-FDA „A“
L20: Eintrittskörper J48: PCTFE „G“
J49: VESPEL-SP1 „T“
Heizmantel
H29
Sonderwerkstoffe Sonderwerkstoffe
2.4610 Hastelloy® C4 2.4610 HASTELLOY C4
2.4360 Monel® 400 2.4360 MONEL 400
1.4462 Duplex 1.4462 DUPLEX
Code
YYYY
Code
YYYY
Code Code
Code Code
XXXX ZZZZ
XXXX ZZZZ
01/14 LWN 481.01-D

Type 437
Anwendungsbereich von konventioneller Ausführung und Long version
Type 437
Anwendungsbereich
Long version
D/G/F D/G
D/G/F Engster d0 [mm] 6
Type 4373
Engster Strömungs-
Engster Strömungs- d0 [mm] 10 d0 [mm] 10 durchmesser d0 [inch] 0,236
Strömungs-
durchmesser d0 [inch] 0,394 d0 [inch] 0,394
durchmesser Engster A0 [mm2] 28,3
Engster Strömungs-
Engster Strömungs- A0 [mm2] 78,5 A0 [mm2] 78,5 querschnitt A0 [inch2] 0,044
Strömungs-
querschnitt A0 [inch2] 0,122 A0 [inch2] 0,122
querschnitt
Baugruppe Werkstoffe
Baugruppe Werkstoffe Baugruppe Werkstoffe
Eintritts- 1.4404 stellitiert
Eintritts- 1.4104 Eintritts- 1.4104 körper SA 479 316L
körper SA 479 430 körper SA 479 430 stellitiert
Teller 1.4122 Teller 1.4122 Teller 1.4404 stellitiert
Edelstahl Edelstahl SA 479 316L
gehärtet gehärtet stellitiert Ansprechdruck
p [psig]
0 986 1349 2611 4786 5294 5511

0 68 93 180 330 365 380
Ansprechdruck
Long version p [bar]
Momentan keine TÜV-Zulassung für
D/G/F D/G thermische Expansion verwendbar.
Type 4374
Strömungs-
Engster Engster d0 [mm] 10 durchmesser d0 [inch] 0,236
d0 [mm] 10
Strömungs- Strömungs-
d0 [inch] 0,394 Engster A0 [mm2] 28,3
durchmesser d0 [inch] 0,394 durchmesser
Strömungs-
Engster A0 [mm2] 78,5 Engster A0 [mm2] 78,5 querschnitt A0 [inch2] 0,044
querschnitt A0 [inch2] 0,122 querschnitt A0 [inch2] 0,122
Baugruppe Werkstoffe Baugruppe Werkstoffe Eintritts- 1.4404 stellitiert
körper SA 479 316L
Eintritts- 1.4404 Eintritts- 1.4404
stellitiert
körper SA 479 316L körper SA 479 316L
Teller 1.4404 stellitiert
Teller 1.4404 Teller 1.4404 SA 479 316L
SA 479 316L SA 479 316L stellitiert
01/20 LWN 481.01-D

Zusatzausrüstungen Serie 437
Verfügbare Anschlüsse
Für Abmessungen und Gewichte siehe:
Type 437 – Seite 01/08 + 01/10
Type 438 – Seite 02/08 + 02/10
Type 439 – Seite 03/08 + 03/10
Außengewinde Innengewinde
Gewindeanschlüsse
Verfügbar für die gesamte Serie 437
Ventilgröße Option code Eintritt Option code Austritt

Außengewinde DIN ISO 228-1
3/
8" V49 ✓ – –
1/
2 " V54 ✓ – –
G
✓
Zusatzausrüstungen
3/
4" V55 – –
1" V56 ✓ – –
Innengewinde DIN ISO 228-1
1/
2" V50 ✓ V65 ✓
G 3/
4" V51 ✓ V76 ✓
1" V52 ✓ V66 ✓
Außengewinde DIN ISO 7-1/BS 21
1/
2" V30 ✓ – –
R/BSPT 3/
4" V31 ✓ – –
1" V32 ✓ – –
Innengewinde DIN ISO 7-1/BS 21
1/
2" V38 ✓ V34 ✓
Rc/BSPT 3/
4" V39 ✓ V35 ✓
1" V40 ✓ V36 ✓
Außengewinde ANSI/ASME B1.20.1
1/
2" V61 ✓ – –
NPT 3/
4" V62 ✓ – –
1" V63 ✓ – –
Innengewinde ANSI/ASME B1.20.1
1/
2" V58 ✓ V70 ✓
NPT 3/
4" V59 ✓ V71 ✓
1" V60 ✓ V72 ✓
Flansch- und Gewindeanschüsse können kombiniert werden
Gewinde nach anderen Normen sind erhältlich
Bitte den Durchmesser, Druckbereich und Norm spezifizieren.
04/04 LWN 481.01-D

Type 437 – Seite 01/09 + 01/11
Type 438 – Seite 02/09 + 02/11
Type 439 – Seite 03/09 + 03/11
Flaschanschluss
Flanschanschlüsse
Flanschdruckstufe Option code Eintritt Option code Austritt

DIN ISO 1092-1 (PN > 100: DIN 2501)
40 I21 ✓ I40 ✓
160 I22 ✓ I41 ✓
✓ ✓
Zusatzausrüstungen
DN 15 250 I23 I42
320 I24 ✓ – –
400 I25 ✓ – –
40 I26 ✓ I43 ✓
DN 20 160 I27 ✓ I44 ✓
250 – – – –
40 I31 ✓ I46 ✓
160 I32 ✓ I47 ✓
DN 25 250 I33 ✓ I48 ✓
320 I34 ✓ – –
400 I35 ✓ – –

ANSI/ASME B 16.5
150 V01 ✓ V24 ✓
300 V02 ✓ V13 ✓
600 V02 ✓ V13 ✓
NPS 1/2"
900 V03 ✓ V14 ✓
1500 V03 ✓ – –
2500 V04 – – –
150 V05 ✓ V15 ✓
300 V06 ✓ V16 ✓
600 V06 ✓ V16 ✓
NPS 3/4"
900 V07 ✓ V17 ✓
1500 V07 ✓ – –
2500 V08 ✓ – –
150 V09 ✓ V18 ✓
300 V10 ✓ V19 ✓
600 V10 ✓ V19 ✓
NPS 1"
900 V11 ✓ V20 ✓
1500 V11 ✓ – –
2500 V12 ✓ – –
LWN 481.01-D 04/05

Type
437
Safety Relief Valves
– spring loaded
Metric Units
Facts
LWN 461.01-E
Type 437
Available designs
Type 437
40 Cap H2
18 Adjusting screw
with bushing Axial needle 69
19 Lock nut beering

16 Spring plate
12 Spindle
54 Spring
2 Outlet body
17 Spring plate
57 Pin
61 Ball
7 Disc
1 Body
Conventional design Long version

Threaded connection Threaded connection
Outlet flange 2.4
Outlet adaptor 2.1
Inlet flange 48
Conventional design
Flange connection
01/02 LWN 481.01-E

Type 437
Available designs – materials
Type 437
Materials
Item Component Remarks Type 4373 Type 4374
Threaded 1.4104 1.4404

connection SA 479 430 SA 479 316L
1.4404 1.4404
1 Base / Inlet body Flange connection
SA 479 316L SA 479 316L
1.4404 Stellited 1.4404 Stellited
Long version
SA 479 316L Stellited SA 479 316L Stellited
1.4104 1.4404
2 Outlet body
SA 479 430 SA 479 316L
1.4404 1.4404
2.1 Outlet adaptor Flange connection
316L 316L
1.4404 1.4404
2.4 Outlet flange Flange connection
316L 316L
1.4122 1.4404
Hardened stainless steel SA 316L
7 Disc
Long version
316L Stellited 316L Stellited
1.4021 1.4404
12 Spindle
420 316L
1.4104 1.4404
16/17 Spring plate
Chrome steel 316L
Adjusting screw 1.4104 / PTFE 1.4104 / PTFE
18
with bushing Chrome steel / PTFE 316L / PTFE
1.0718 1.4404
19 Lock nut
Steel 316L
1.0718 1.4404
40 Cap H2
Steel 316L
1.4404 1.4404
48 Inlet flange Flange connection
316L 316L
1.4310 1.4310
54 Spring
Stainless steel Stainless steel
1.4310 1.4310
57 Pin
1.3541 1.4401
61 Ball
Hardened stainless steel 316
1.4404 1.4404
69 Axial needle beering Long version
316L 316L
Please notice:
– Modifications reserved by LESER.

– LESER can upgrade materials without notice.
– Every part can be replaced by other material acc. to customer specification.
LWN 481.01-E 01/03

Type 437
How to order – Article numbers
Type 437
Article numbers
Conventional design
Actual Orifice diameter d0 [mm] 10
Actual Orifice area A0 [mm2] 78,5
Actual Orifice diameter d0 [inch] 0,394
Actual Orifice area A0 [inch2] 0,122
Base / Inlet body material: 1.4104 (430)
H2 Art.-No. 4373. 2602

H3 Art.-No. 4373.
pmax = 10 barg 2603
H4 Art.-No. 4373. 2604

p [barg] S/G/L 0,1 – 93
p [psig] S/G/L 1,5 – 1349
Base / Inlet body material: 1.4404 (316L)
H2 Art.-No. 4374. 3142
H4 Art.-No. 4374. 3144

p [barg] S/G/L 0,1 – 68
p [psig] S/G/L 1,5 – 986
Article numbers
Long version
Actual Orifice diameter d0 [mm] 6 6 10
Actual Orifice area A0 [mm2] 28,3 28,3 78,5
Actual Orifice diameter d0 [inch] 0,236 0,236 0,394
Actual Orifice area A0 [inch2] 0,044 0,044 0,122
H2 Art.-No. 4373. 2622 – 2612
H4 Art.-No. 4373. 2624 – 2614

p [barg] S/G/L 180 – 365 – 93 –180
p [psig] S/G/L 2611 – 5294 – 1349 – 2611
H2 Art.-No. 4374. 3122 3132 3153
H4 Art.-No. 4374. 3124 3134 3154

p [barg] S/G 180 – 365 L 180 – 3801) S/G/L 68 –180
p [psig] S/G 2611 – 4786 L 2611 – 5511 S/G/L 986 – 2611
1) At
the moment no TÜV approval, useable for thermal expansion.
Use “Long version” only for set pressure exeeding set pressure range of “Standard” model.
For selection of inlet and outlet connection please refer to page 04/04 – 04/05.
LWN 481.01-E 01/07

Type 437
Dimensions and weights – Metric Units
Threaded connections
Type 437

1/ " 3/ " 1/ 3/ " 1/ " 3/ "
Size Outlet body 2 4 1" 2" 4 1" 2 4 1"
Actual Orifice diameter d0 [mm] 10 10 10 6 6 6 10 10 10
Actual Orifice area A0 [mm2] 78,5 78,5 78,5 28,3 28,3 28,3 78,5 78,5 78,5
Weight [kg] 1,2 1,6 1,6 1,4 2,1 2,1 1,4 2,1 2,1
Required installation diameter [mm] 65 80 80 65 80 80 65 80 80
Inlet thread “Female”
DIN ISO 228-1 G Inlet a 45 55 55 45 55 55 45 55 55
Center to face [mm] Outlet b 30 37 37 30 37 37 30 37 37
Height [mm] H max. 210 220 220 230 240 240 230 240 240
ISO 7-1/BS 21 Rc Inlet a 45 55 55 45 55 55 45 55 55
Height [mm] H max. 210 220 220 230 240 240 230 240 240
ANSI/ASME B1.20.1 NPT Inlet a 45 55 55 45 55 55 45 55 55
Height [mm] H max. 210 220 220 230 240 240 230 240 240
Inlet thread “Male”
DIN ISO 228-1 G Inlet a 33 33 36 33 33 36 33 33 36
ISO 7-1/BS 21 R Inlet a 31 31 34 31 31 34 31 31 34
Height inlet thread “Male”

Inlet thread Size 3/ 1/ 3/ 3/ 1/ " 3/
8" 2" 4" 1" 8" 2 4" 1"
DIN ISO 228-1 [mm] G H max. 210 212 214 216 230 232 234 236
ISO 7-1/BS 21 [mm] R H max. – 215 216 219 – 235 236 239
ASME B1.20.1 [mm] NPT H max. – 218 218 223 – 238 238 243
Length of screwed end “c” inlet thread “Male”

Inlet thread Size 3/ 1/ " 3/
8" 2 4" 1"
DIN ISO 228-1 [mm] G 12 14 16 18
ISO 7-1/BS 21 [mm] R – 19 20 23
ASME B1.20.1 [mm] NPT – 22 22 27
Required installation diameter
Conventional design – Female thread Conventional design – Male thread Long version – male thread
01/08 LWN 481.01-E

Type 437
Flanged connection
Type 437
Actual Orifice diameter d0 [mm] 6 10 6 10
Actual Orifice area A0 [mm2] 28,3 78,5 28,3 78,5
DIN ISO 1092-1 (Available flange sizes refer to page 04/05)
Flange rating PN 40
Center to face [mm] Inlet a 100 100 100 100
Outlet b 100 100 100 100
Height [H4] [mm] H max. 263 263 284 284
Flange rating ≥ PN 160
Outlet b 100 100 100 100
Height [H4] [mm] H max. 266 266 287 287
ASME B 16.5 (Available flange sizes refer to page 04/05)
Flange rating class 150
Outlet b 100 100 100 100
Height [H4] [mm] H max. 263 263 284 284
Flange rating class ≥ 300
Outlet b 100 100 100 100
Height [H4] [mm] H max. 266 266 287 287
Weight
For the calculation of the total weight please use the Formular: WT = WN + WF (Inlet) + WF (Outlet)
Weight net [kg]
2,4 2,4 2,8 2,8
(without inlet and outlet flange) WN
Flange dimensions and availability

DIN ISO 1092-1 / Flange rating PN ASME B16.5 / Flange rating class
Size 40 160 250 320 400 Size 150 300 600 900 1500 2500
DN 15 NPS 1/2"
Flange thickness [mm] s 18 22 26 26 30 14 18 26 30,2
Weight slip on flange [kg] WF 0,8 1,2 2,5 2,5 3,6 0,6 0,9 2,1 3
Available at Inlet ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓
Available at Outlet ✓ ✓ ✓ ✓ ✓ ✓
DN 20 NPS 3/4"
Flange thickness [mm] s 20 22 15 18 25,4 32
Weight slip on flange [kg] WF 1,1 1,3 0,8 1,4 2,3 3,5
Available at Inlet ✓ ✓ ✓ ✓ ✓ ✓
Available at Outlet ✓ ✓ ✓ ✓ ✓
DN 25 NPS 1"
Flange thickness [mm] s 22 26 30 36 40 17 21,5 32,5 40
Weight slip on flange [kg] WF 1,3 2,6 3,5 5 7,5 1 2,1 4,1 5,1
Available at Outlet ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓
a
s s
s s
b
LWN 481.01-E 01/09

Type 437
Pressure temperature ratings
Type 437
Metric Units
Actual Orifice diameter d0 [mm] 6 10
Actual Orifice Area A0 [mm2] 28,3 78,5
Body material: 1.4104 (430)
Base / 3/ 1/ 3/ 3/ " 1/ " 3/
Connection size 8" 2" 4" 1" 8 2 4" 1"
Inlet Body Pressure rating PN 400 PN 250
Outlet body Pressure rating PN 160 PN 160
Minimum
p [barg] S/G/L 180 [S/G only] 0,1
set pressure
Maximum 10 only H3
p [barg] S/G/L 365 [S/G only]
set pressure 180
Temperature min [°C ] -10 -10
acc. to DIN EN max [°C ] +220 +220
acc. to ASME max [°C ] +220 +220
Body material: 1.4404 (316L)
Base / 3/ 1/ 3/ 3/ " 1/ " 3/
Connection size 8" 2" 4" 1" 8 2 4" 1"
Minimum
set pressure
Maximum 10 only H3
set pressure 180
US Units
Actual Orifice diameter d0 [inch] 0,236 0,394
2
Actual Orifice area A0 [inch ] 0,044 0,122
Base /
3/ 1/ 3/ " 3/ 1/ " 3/
Inlet Body Connection size 8" 2" 4 1" 8" 2 4" 1"
Minimum
p [barg] S/G/L 2610 1,
set pressure
Maximum 145 only H3
p [barg] S/G/L 5294
set pressure 2610
Temperature min [°F ] +14 +14
acc. to DIN EN max [°F ] +428 +428
Temperature min [°F ] -20 -20
acc. to ASME max [°F ] +428 +428
Base /
3/ 1/ 3/ " 3/ 1/ " 3/
Minimum
p [barg] S/G/L 2610 1,5
set pressure
Maximum 145 only H3
p [barg] S/G/L 5294
set pressure 2610
01/12 LWN 481.01-E

Type 437
Available Options
Type 437
Male thread Female thread Flanged version
Stellited sealing surface Disc with inserted sealing plate

J25: Disc stellited J44: PTFE-FDA “A”
L20: Base/inlet body J48: PCTFE “G”
J49: VESPEL-SP1 “T”
Heating jacket
H29
Special material Special material

2.4360 Monel® 400 2.4360 MONEL 400
Code
YYYY
Code
YYYY
Code Code
Code Code
XXXX ZZZZ
XXXX ZZZZ
01/14 LWN 481.01-E

Type 437
Application range of conventional design and long version
Type 437
Application range
Long version
S/G/L S/G
Conventional design
S/G/L
Act. Orifice d0 [mm] 6
Type 4373
Act. Orifice d0 [mm] 10 Act. Orifice d0 [mm] 10 diameter [inch] 0,236

diameter [inch] 0,394 diameter [inch] 0,394 Act. Orifice A0 [mm2] 28,3
Act. Orifice A0 [mm2] 78,5 Act. Orifice A0 [mm2] 78,5 area [inch2] 0,044
area [inch2] 0,122 area [inch2] 0,122
Components Materials
Components Materials Components Materials
Base / 1.4404 Stellited
Base / 1.4104 Base / 1.4104 Inlet Body SA 479 316L
Inlet Body SA 479 430 Inlet Body SA 479 430 Stellited
Disc 1.4122 Disc 1.4122 Disc 1.4404 Stellited
Hardened Hardened SA 479 316L
stainless steel stainless steel Stellited Set pressure
p [psig]
0 986 1349 2611 4786 5294 5511

0 68 93 180 330 365 380
Set pressure
Also useable above 330 bar (4786 psig) but
S/G/L S/G TÜV requirements will not be fulfilled
Conventional design
S/G/L
Type 4374
Act. Orifice d0 [mm] 10 diameter [inch] 0,236

diameter diameter [inch] 0,394 Act. Orifice A0 [mm2] 28,3
[inch] 0,394
Act. Orifice A0 [mm2] 78,5 area [inch2] 0,044
Act. Orifice A0 [mm2] 78,5
area area [inch2] 0,122
[inch2] 0,122
Components Materials Components Materials Base / 1.4404 Stellited
Inlet Body SA 479 316L Inlet Body SA 479 316L Stellited
Disc 1.4404 Stellited
Disc 1.4404 Disc 1.4404 SA 479 316L
SA 479 316L SA 479 316L Stellited
01/20 LWN 481.01-E

Accessories and Options
Available connections
For dimensions and weights refer to:
Type 437 – page 01/08 + 01/10
Type 438 – page 02/08 + 02/10
Type 439 – page 03/08 + 03/10
Male thread Female thread

Available for complete 437 series
Valve size Option code Inlet Option code Outlet

Male thread DIN ISO 228-1
3/
8" V49 ✓ – –
1/
2 " V54 ✓ – –
G 3/
4" V55 ✓ – –
1" V56 ✓ – –
Options
Female thread DIN ISO 228-1

1/
2" V50 ✓ V65 ✓
G 3/
4" V51 ✓ V76 ✓
1" V52 ✓ V66 ✓
Male thread DIN ISO 7-1/BS 21
1/
2" V30 ✓ – –
R/BSPT 3/
4" V31 ✓ – –
1" V32 ✓ – –
Female thread DIN ISO 7-1/BS 21
1/
2" V38 ✓ V34 ✓
Rc/BSPT 3/
4" V39 ✓ V35 ✓
1" V40 ✓ V36 ✓
Male thread ANSI/ASME B1.20.1
1/
2" V61 ✓ – –
NPT 3/
4" V62 ✓ – –
1" V63 ✓ – –
Female thread ANSI/ASME B1.20.1
1/
2" V58 ✓ V70 ✓
NPT 3/
4" V59 ✓ V71 ✓
1" V60 ✓ V72 ✓
Flanged and threaded connections can be combined.
Threads according to other standards are available.
Please specify in writing (diameter, pressure rating, standard).
04/04 LWN 481.01-E

Type 437 – page 01/09 + 01/11
Type 438 – page 02/09 + 02/11
Type 439 – page 03/09 + 03/11
Flanged version
Flanged connections
PN Option code Inlet Option code Outlet

DIN ISO 1092-1 (PN > 100: DIN 2501)
40 I21 ✓ I40 ✓
160 I22 ✓ I41 ✓
DN 15 250 I23 ✓ I42 ✓
320 I24 ✓ – –
Options
400 I25 ✓ – –
40 I26 ✓ I43 ✓
DN 20 160 I27 ✓ I44 ✓
250 – – – –
40 I31 ✓ I46 ✓
160 I32 ✓ I47 ✓
DN 25 250 I33 ✓ I48 ✓
320 I34 ✓ – –
400 I35 ✓ – –
Class Option code Inlet Option code Outlet

ANSI/ASME B 16.5
150 V01 ✓ V24 ✓
300 V02 ✓ V13 ✓
600 V02 ✓ V13 ✓
NPS 1/2"
900 V03 ✓ V14 ✓
1500 V03 ✓ – –
2500 V04 – – –
150 V05 ✓ V15 ✓
300 V06 ✓ V16 ✓
600 V06 ✓ V16 ✓
NPS 3/4"
900 V07 ✓ V17 ✓
1500 V07 ✓ – –
2500 V08 ✓ – –
150 V09 ✓ V18 ✓
300 V10 ✓ V19 ✓
600 V10 ✓ V19 ✓
NPS 1"
900 V11 ✓ V20 ✓
1500 V11 ✓ – –
2500 V12 ✓ – –
LWN 481.01-E 04/05

Betriebsanleitung Operating instructions
Ausgabe Oktober 2005 October 2005 edition
Instructions de service Instrucciones de servicio

Edition octobre 2005 Edición octubre 2005
40
18
16
12
H
54
55
56
60
NPSOutlet
DNAustritt
7
a
do
DNEintritt
NPSInlet
b
The Safety Valve

201469_2 Betriebsanleitung 05 08.11.2005 10:44 Uhr Seite 18
E
40 Lifting device
18 Adjusting screw
16 Spring plate
9 Bonnet
12 Spindle
H
54 Spring
55 Stud bolt
56 Hexagonal nut
60 Seal
NPSOutlet
DNAustritt
8 Guide
7 Plate
Seat
a
1 Body
do
DNEintritt
NPSInlet
b
18
1 Contents The following risks could ensue:

a.) The safety valve does not work correctly or is
1 Contents 17 dimensioned incorrectly: the pressure
2 General 17 equipment bursts. Hazard caused by the
3 Testing/marking 17 bursting itself and by the hot, poisonous and
4 Pressure 18 aggressive medium.
5 Function of a safety valve 18 b.) The safety valve operates correctly; medium
6 Functional tightness of a safety valve 19 escapes: there is a risk of hot, poisonous
7 Medium 19 and aggressive medium.
8 Temperatures of the medium and ambient c.) The safety valves leaks: there is a risk of hot,
temperatures 20 poisonous and aggressive medium.
9 Choice of spring 20 d.) Other dangers caused by handling the safety
10 Safety valves with bellows 21 valves e.g., risk of injury from sharp edges, E
11 Safety valves with blow-down ring 21 heavy weight, ...
12 Safety valves built into installations 21
12.1 Open bonnet 21 In order to minimise the risks of these hazards,
12.2 Regular lifting operation 21 the operating instructions must be adhered to at
12.3 Forces acting on the safety valve 21 all times and given priority over the
12.4 Connections 21 recommendations below. The operating
12.5 Direction of safety valves 21 instructions have been developed by practical
12.6 Flow-through 22 experience and from the requirements stipulated
12.7 Condensation 22 in the regulations.
12.8 Transfer of vibrations from the installation 22
12.9 Discharge pipe 22 Sets of rules and standards:
12.10 Unfavourable environmental conditions 23 • Pressure Vessel and Steam Boiler Ordinance
12.11 Leaks caused by foreign bodies 23 • TRD 421, 721
12.12 Protection during storage and transport 23 • TRB 403
12.13 Corrosion protection 23 • AD 2000-Merkblätter A2 and A4
12.14 Maintenance 23 • DIN EN ISO 4126
12.15 Identification of safety valves 23 • Pressure Equipment Directive 97/23/EC
12.16 Lever safety valves 23 • ASME Code Section II and VIII
13 Setting instructions for spring loaded • API 526, 520, 527
safety valves 23 • Others.
13.1 Lifting device H3 23
13.2 Lifting device H4 24 LESER is in possession of the appropriate
13.3 Spring replacement 24 product-related certificates to prove that the sets
14 Handling 25 of rules and standards are fulfilled and that safety
15 Supplementary loading system 25 is therefore guaranteed.
16 Combined Safety Valve and Bursting Disc 26
17 Unexpected conditions 26 LESER is certified according to:
18 Product overview 26 • DIN EN ISO 9001/2000 (Quality Management
19 Assembly instructions 26 System)
20 Disclaimer 26 • DIN EN ISO 14001/2005 (Environmental Manage-
ment System)
• Modul D of the Pressure Equipment Directive
2 General (quality assurance in production)
• ASME VIII (UV) and
The following general notes refer to directly • KTA 1401
loaded and controlled safety valves (with This ensures that all requirements for quality and
supplementary loading system). environment are complied with.
To fulfill its function all components of a safety

valve are manufactured to great precision. Only 3 Testing/marking
this precision allows correct functioning. Safety
valves must therefore be handled with care. After setting and testing, each safety valve is
Failure could endanger people, animals and sealed by LESER or by the expert of an official
installations. Even with a correctly functioning acceptance organisation at the customer’s
safety valve hazards may occur. This has to be request (such as TÜV, Germanischer Lloyd, ...).
taken into account.
If the marking of the safety valve is applied on the
valve body by means of a marking stamp, the
safety valve must not be damaged by such
stamping. Deformation of the valve may cause
leakage or destruction of the safety valve. Thin-
19
walled valve bodies should not be stamped. produced, which acts on the rear side of the disc.
This increases the set pressure by exactly the
Safety valves have a name plate showing the value of this pressure. If the superimposed back
following data: pressure is constant, it is possible to adjust the
• Date of order (Serial-No.) differential pressure by reducing the value of the
• Technical data test pressure by the value of the back pressure
• Test pressure (test pressure set pressure).
• VdTÜV type test approval number
• CE-marking and identification number of the If there is no superimposed back pressure, the
notified body. set pressure will drop. The back pressure
intended must not be exceeded because then it
For safety valves without type test approval, only would also exceed the set pressure.
E order data and technical data are included.
The maximum pressure that a safety valve may
Further marks required are either moulded into
be operated at regardless of the test pressure
the casting, or, for safety valves with threaded
depends on a number of factors.
connections, punched in. Safety valves with a
Among these are:
heating jacket have a separate name plate for the
• Materials
heating jacket.
• Medium temperature
If technical changes are made, always check • Design pressure
whether the identification has to be adjusted. • Flange classes
Modifications on valves or identifications may • Others.
only be carried out by trained personnel (refer to
section 12.14). These should be taken into consideration when
selecting a safety valve.
4 Pressure The value of the operating pressure must

permanently be lower than the reseating pressure
Definitions: difference plus 5%. Otherwise LESER cannot
a) Test pressure: the pressure that the safety guarantee that the valve will close securely after
valve is set to at LESER’s. The outlet side of the opening (exception: if the valve is fitted with a
safety valve is open to atmospheric pressure. supplementary loading system, refer to section 15).
b) Set pressure: the predetermined pressure at
which a safety valve under operating
conditions commences to open. 5 Function of a safety valve
c) Overpressure: a pressure increase over the
set pressure, at which the safety valve attains A performance certificate is required to ensure
the lift specified by the manufacturer, usually that the required mass flow is discharged by the
expressed as a percentage of the set safety valve if necessary.
pressure.
d) Reseating pressure: the value of the inlet Pipes leading to the safety valve have to be fitted
static pressure at which the disc re- so that large hydrodynamic losses are prevented.
establishes contact with the seat or at which The edges at the pipe inlet should be at least
the lift becomes zero. chamfered, but preferably rounded. The notes on
e) Operating pressure: the pressure at which dimensioning given in the regulations, standards
the plant operates. and manufacturer’s information sheets must be
f) Built-up back pressure: the pressure existing adhered to.
at the outlet of a safety valve caused by flow
through the valve and the discharge system. Safety valves may only be disabled by means of
g) Superimposed back pressure: the pressure shut-off valves provided that the pressurised
existing at the outlet of a safety valve at the equipment is protected against excessive
time when the device is required to operate. pressure by other safety devices or that the plant
h) Back pressure: the total of built up and or equipment is shut down altogether.
superimposed back pressure.
Safety valves are guaranteed to work perfectly, if
Pressure shall be stated as overpressure [bar g or
the built-up back pressure on the outlet side does
psig] above atmospheric pressure.
not exceed 15% of the test pressure minus the
Unless stated otherwise, the pressure specified superimposed back pressure (if available).
by the customer is set with atmospheric pressure
acting on the outlet side (test pressure = set Built-up and superimposed back pressures may
pressure). be compensated by an amount not exceeding
35% of the set pressure by using stainless steel
If there is pressure on the outlet side bellows specially designed for this, which
(superimposed back pressure), a force is compensates the force acting on the rear side of
the disc. Function and set pressure remain
20
constant. If it is not clear whether the bellows Sealing surfaces are machined with great
compensate for pressure, LESER should be precision. A tight seal is achieved, for instance,
contacted. The application limits of the bellows by hardening, tempering, precision-grinding and
for pressure and temperature must not be lapping. This makes safety valves vulnerable to
exceeded (refer to section 10). impact damage; they may, for example, develop
leaks as a result of vibrations.
If discharge lines are fitted with equipment, which
prevents the ingress of rainwater or foreign The following notes are to be observed:
bodies, such equipment must not obstruct or • During transport, installation and operation
restrict the outlets of the safety valve. safety valves must be protected from vibra-
tions.
The blow-off pipe should be dimensioned using • Safety valves must be transported with care, e.g.,
the maximum back pressure and the appropritate the lever must never be used as a carrying handle E
temperature. It should be installed in a pipe run, and the safety valve must not be dropped.
which is free from restrictions and turbulences
and should not be opposite other branches, to The force between the seat and the disc falls as a
ensure that it does not impair the functioning of function of rising operating pressure. Therefore
the valve or damage it. The capacity and the probability of leaks also rises if the operating
functioning of safety valves must also be ensured pressure is close to the set pressure (refer to
in applications, where blow-off systems fulfill section 4). Damaged or contaminated sealing
several functions. surfaces in particular tend to develop leaks.
During blowing-off, reaction forces act on the

safety valve itself, the pipes connected to it and 7 Medium
the fixed mounts. The size of the reaction force is
particularly important for the dimensioning of the Any moving parts have to be protected from
fixed mounts. abrasive/corrosive media to avoid the risk of
jamming, seizing or sticking. This can be done by
The following points have to be taken into con- servicing the valve each time it has opened or by
sideration: using stainless steel/elastomer bellows. The
• Static, dynamic or thermal loads exerted by the limits of application for the bellows have to be
pipe leading to or from the safety valve must observed.
not act on the valve.
• Safety valves must be fixed as specified in the The possibility of leaking sealing surfaces caused
drawing. Omitting or removing mounts can by abrasive media must be considered.
result in damage because this results in Dangerous media must not be allowed to enter
excessively large forces or tensions. the environment. In case of doubt the safety valve
• Also refer to section 12.3. should be replaced after opening.
Soft sealing discs can compensate for minor

6 Functional tightness of a safety valve damage to the seat. In every case the limits of
application and medium consistency for the
One has to expect a slight leakiness with all elastomer material have to be observed.
safety valves fitted with metal seals. People,
environment and installations must not be The strength of components (e.g. body, spindle,
endangered by the escaping medium. spring) may be reduced by abrasion. This may
lead to leaking or to the bursting of pressure
Safety valves with soft seals seal are much more equipment. If abrasive media are used, main-
reliable than those with metal soft seals. LESER tenance intervals should be shortened.
offers a range of elastomer materials for different
applications. The elastomers must match the Sealing surfaces must not stick together.
medium and its pressure and temperature. This can be prevented by:
• Regular lifting operation (refer to section 12.2)
All LESER products are inspected for damage • Heating or cooling to prevent the seat from
and leaks. In order to prevent damage during sticking
transport all products have their flange faces, • Other measures which prevent sticking.
sealing lips and pipe threads protected before
being packed for shipment. This protection Corrosion damage to body parts and inner parts
should be removed before assembly (refer to cannot always be spotted easily. Therefore the
section 12.12). user must make sure that the medium does not
attack or corrode the materials the safety valve is
Before installing the valve in the plant or pipeline made from. If this possibility cannot be excluded,
system it should be inspected for damage. Once monitoring and servicing have to be adapted to
installed, the valve should be checked for leakage this situation accordingly. Special materials can
while the plant or pipeline system is operating. be selected on request.
21
Lubricants based on mineral oils are used as an Contact with hot or dangerously cold safety valve
aid during installation. These fluids can surfaces must be prevented by appropriate
contaminate the medium unless special protective measures.
precautions are taken.
The following points have to be observed:
• Lubricants/auxiliary fluids can reach the 9 Choice of spring
medium and contaminate it or cause a chemical
reaction. The springs used by LESER are designed for
• Lubricants can be washed out and make the defined pressure ranges. The test pressure is
dismantling of the safety valve more difficult. always the basis for selecting the spring (refer to
• Safety valves can be designed as oil and section 4). The functioning of the springs is
grease-free types. For these types of valves all ensured if the spring is designed and used in
E residues containing mineral oil are removed conformity with the sets of rules.
from the valve sufaces and special lubricants
are used. When dismantling the valves, the springs must
• Bellows prevent contact between medium and not be mixed up as the functioning will be
lubricant. impaired, if the wrong spring is installed. In
extreme cases the spring will be fully
compressed (the coils touch each other) and the
8 Temperatures of the medium and ambient safety valve does not work.
temperatures
When changing the test pressure the user must
Minimum and maximum temperatures are given check whether the spring/springs can be used at
for LESER safety valves. They always refer to the the new pressure. This can be done by using
temperature of the medium, which may current LESER spring tables. If they are not
simultaneously be the ambient temperature. available please contact LESER. If the spring is
Therefore, the ambient temperature has to be not suitable for the new test pressure it must be
taken into consideration under extreme climatic replaced by a suitable spring. If the test pressure
conditions such as are found in Scandinavia. of a safety valve is altered, the whole safety valve
and its dimensioning must be checked for
It is necessary to observe the effect of suitability.
temperatures of the medium on the maximum
permitted pressure. If expansion limits drop at LESER springs bear clear identification marks.
higher temperatures or if the medium tends to be Springs which can no longer be identified or
brittle at low temperatures, the maximum permitted damaged springs must not be used.
temperatures must be lowered. Please observe the
specifications/regulations in the appropriate sets of Springs must not be reused if it cannot be
rules and the manufacturer’s specifications. estimated how many load changes they have
been subjected to. This applies in particular to
If the safety valve is supposed to be thermally the springs of safety valves which have been
insulated, the bonnet and the cooling zones (if exposed to vibrations, as in this case the actual
there are any) must not be covered to protect the number of load changes is practically impossible
springs from becoming overheated. to estimate.
To set a safety valve for a particular pressure at a The springs used in LESER safety valves have
higher ambient temperature, a correction factor been matched to the materials used in these
should be used to allow for the increased valves. In unfavourable cases, there may be
temperature. This eliminates the necessity of factors leading to increased temperature or
adjusting the setting while the medium is at the corrosion that make the following actions
higher temperature (procedure: Cold differential necessary:
test pressure according to LESER work standard Temperature effects:
LWN 001.78). As spring temperatures depend on many external
conditions, no general temperature of the medium
During the operation of safety valves, medium can be specified as the limit of application. It has
can freeze, which prevents opening and closing. to be evaluated in every single case, which of the
This can happen if the temperature falls below following measures need to be taken:
the freezing point of the medium. In case of • Using spring materials that are heat resistant or
media, which congeal at low temperatures, the tough at subzero temperatures
viscosity may drop significantly. If the medium • Providing the test pressure with a correction
contains freezing vapours, the risk of icing-up is factor to compensate for a drop of set pressure
increased by the expansion of gases as this at higher temperatures (refer to section 8 for
causes the temperature to fall further. If there is cold adjustment)
danger of icing, measures must be taken to • By using highly heat-resistant materials in
ensure that the safety valve works correctly. conjunction with cooling zones, open bonnets
22
and bellows, the effect of the temperature on movable parts (e.g., the spring) as otherwise
the spring is reduced. there is a danger of jamming. Medium can leak
out of the open bonnets or open spindle guides
Corrosion effects: of lever safety valves. The user must ensure
• Medium may enter into the spring chamber if that leaking medium cannot cause hazards.
safety valves do not have bellows. Corrosive/ A sufficient safety distance has to be observed.
abrasive media reduce the fatigue strength.
This should be taken into consideration when 12.2 Regular lifting operation
selecting, sizing and servicing safety valves. Safety valves must be vented regularly in order
• Spring materials with increased corrosion to check their function and to remove residues.
resistance may be used (e.g., stainless steel, They can be opened if at least an operating
Hastelloy, ...) pressure of ≥ 75% of the set pressure is
reached. Exceptions can only be allowed if the E
functioning is checked regularly in a different
10 Safety valves with bellows way, e.g., by appropriate short maintenance
intervals. The valid regulations for the
The pressure and temperature application limits application of safety valves have to be adhered
of bellows must be complied with. to.
Defective bellows are recognisable by the After lifting, the lever must move freely, i.e. the
medium leaking out of the open bonnet or the lifting fork in the lifting device must not acting
vent hole. Hazards from leaking medium must be on the spindle cap.
prevented.
12.3 Forces acting on the safety valve
Measures against leaking medium: Safety valves must not be subjected to
• Equipping the valve with an inspection excessive static, dynamic or thermal stresses.
manometer and a drip container. These can be caused by:
• In the case of open bonnets, the leaking of the • Installation under tension (static)
medium cannot be prevented if the bellows are • Reaction forces when blowing off (static)
defective. Hazards have to be prevented, (e.g., by • Vibrations (dynamic)
a sufficient safety distance, protection equipment • Temperature expansion (thermal)
or by using only non-hazardous media).
The following precautions should be taken:
Defective bellows must be replaced immediately • The system must be able to expand
in order to ensure the correct function of the • Pipe runs must not be fixed in a way that
safety valve. they are under tension.
Stainless steel bellows for which the number of • The safety valve brackets should be used for
permitted load changes has been exceeded, or is attaching the valve securely to the plant.
unknown, must be replaced. As a rule bellows • Vibration of the safety valve and plant should
should be replaced whenever the valve is dis- be prevented.
mantled.
12.4 Connections
Moisture or dirt must not be allowed to enter the The connections/seals between the safety valve
bonnet via the vent hole. Appropriate protective and the plant shall be of sufficient size. They
measures (e.g., connections, pipes,...) must be also have to be designed in accordance with
taken. the sets of rules to prevent the connection from
failing (also refer to sections 4 and 8).
11 Safety valves with blow-down ring The user is responsible for the correct fitting of
seals for pipes leading into the valve and pipes
Safety valves with blow-down ring, like type 526, for blowing-off or other connections to the
are always delivered with the blow-down ring in safety valves. Therefore LESER will not accept
the lowest position. That is, that the blow-down any liability for these.
ring is screwed into the nozzle, until the lower
stop is reached. The blow-down ring is arrested For correct installation the user should ensure
with a lock screw, which is sealed. The position that the flange sealing surfaces are not
of the blow-down ring must not be changed. damaged during installation.
12.5 Direction of safety valves

12 Safety valves built into installations Confirmation by the TÜV Nord:
Directly-loaded safety valves are to be installed
12.1 Open bonnet in accordance with AD 2000-Merkblatt A2
For open bonnets or lever valves, appropriate “upright with respect to the flow direction”:
measures must be taken to avoid contact with
23
In addition AD 2000-Merkblatt A2 requires that • The blow-off pipe must be provided with a
“safety valves must correspond to the state-of- sufficiently large condensation drainage pipe,
the-art and be suitable for the purpose for which must be attached to the lowest point
which they are deployed”. of the pipe. For pipes larger than nominal
diameter 40 mm the drainage pipe must
Under the following conditions it is possible to have a nominal diameter of at least 20 mm.
deviate from the upright installation direction, (In case of steam applications even larger
and in our view it is also permissible. diameters may be necessary. In such cases
E.g., the safety valves have been granted type the regulations must be observed).
approval for non-upright installation and a note • LESER safety valves are not provided with a
to this effect is found in the VdTÜV-Merkblatt. drain hole as the drainage must be executed
If adequate experience of installing safety valves via the blow-off pipe.
E in a direction other than upright is available over Exceptions: Certain regulations require
an extended period, this type of installation drainage holes (e.g., on ships with variable
is permissible if agreed between operator, orientation in the water and a pipe slope).
manufacturer and the technical inspector, who Safety valves which are intended for such
authorises the installation. If applicable, purposes are equipped with a drainage hole.
additional measures may need to be taken with Such designs are only manufactured if they
regard to this installation. are specifically ordered.
• It is possible to drill a drain hole later at the
Therefore safety valves may, according to the place intended for this purpose.
information provided above, be installed in Caution: swarf can cause damage which
directions other than the one specified in AD may lead to leaks or to the failure of safety
2000-Merkblatt A2. valves.
• Drainage pipes must be installed sloping
If the conditions mentioned above have been downwards; these pipes must have no
fulfilled, the following points have to be restrictions such as locally reduced
observed when installing the valve in a direction diameters. There must be an unobstructed
other than upright: view of the drain outlet; any risks resulting
• Drainage has to be fitted to drain medium or from leaking medium must be prevented.
condensation from components which are (e.g., by fitting condensation traps, drip
important for the function of the valve. container, filters, etc.)
• Servicing procedures should be modified, • Unused drainage holes must be closed.
e.g., the functioning of the drainage system
must be ensured.
• LESER must be informed about the type of 12.8 Transfer of vibrations from the installation
installation in order to be able to agree to a Any vibrations which might be transferred to the
direction deviating from upright. safety valve must be prevented. If this is not
possible the safety valve must be decoupled
12.6 Flow-through from the installation, e.g., via bellows, pipe
The flow direction must be observed during bends, ...
installation. It can be recognised by the
following features: Pressure variations or surges in the medium
• Flow direction arrow on the body also may lead to dangerous vibrations of the
• Diagrams in the safety valve. This also has to be prevented.
– Complete Catalogue
– Operating instructions If the transfer of vibrations cannot be
– Data sheets and prevented, damping systems can be built in,
– Assembly instructions. e.g., o-ring dampers.
12.7 Condensation 12.9 Discharge pipe

Medium or condensation must be drained from When a safety valve blows off, in addition to the
the outlet chamber of the safety valve or such general hazards from the medium, the following
components, which are important to the hazards have to be expected (refer to section 2):
functioning of the valve (spring, bellows etc.). • High flow rates
• High temperatures
The following points should be noted: • Noise emissions
• Drainage should always be carried out via the
blow-off pipe, which should be installed sloping In this context the following points should be
downwards so that it can drain itself (figure 3). noted:
• Directly downstream of the safety valve there • For steam or gases the blow-off pipe should
must be no upward bend as in this case point upwards in order to allow blowing off
correct drainage would not be possible without danger.
(figure 4).
24
• For liquids the blow-off pipe should point In the case of lever safety valves, the wooden
downwards so that the medium can wedge, which protects the sealing surfaces
completely drain out of the blow-off from damage during transport, has to be
chamber. removed.
• The outlet flange of safety valves or blow-off
pipes must be directed so that no danger is 12.13 Corrosion protection
caused by the medium blowing off. The Moving parts and parts important to the
following options are available: operating of the valve must not be impaired in
- Blowing off into a container their motion, e.g. the blowing-off chamber. The
- Safety valve and blowing-off pipes without spindle guide must not be varnished.
direct access
- Design with silencer. The supplementary loading system must not be
coated with protective paint (refer also to E
12.10 Unfavourable environmental conditions section 15).
All LESER safety valves which may corrode are
coated with a protective coating during 12.14 Maintenance
manufacture which protects the safety valve Safety valves may only be serviced by skilled
during storage and transport. In corrosive staff.
environments a further corrosion protection is
required (refer to section 12.13). For extreme Maintenance intervals cannot be specified by
conditions, LESER recommends stainless steel LESER as they depend on many factors:
safety valves. The supplementary loading • Corrosive, aggressive and abrasive media
system must not be given a protective coating! lead to rapid wear and require shorter main-
tenance intervals
External media (e.g., rain water or dirt/dust) • Frequent operating requires shorter main-
must not enter the blowing-off pipe or come in tenance intervals
contact with functional components (e.g., • Maintenance intervals have to be agreed
guides with open bonnets) have to be avoided. between the operator, the inspector and the
By analogy, the statements made in section 7 manufacturer. Inspections must be carried
apply. out at the time of the regular external and
Simple preventive measures are possible: internal checks of the pressure equipment.
• Protection of the blow-off chamber from
extraneous media and dirt 12.15 Identification of safety valves
Before assembling safety valves the
• Protection of the parts important to documentation must be checked in order to
operating from external media and dirt. ensure that the correct valve has been selected
for the assembly.
12.11 Leaks caused by foreign bodies
Foreign bodies must not remain in the 12.16 Lever safety valves
installation (e.g., welding beads, sealing The set pressure of lever safety valves is
material such as hemp tape, PTFE tape, defined by the mass and the position of the
screws, etc.). One option for avoiding foreign loading weights. It is not allowed to change
bodies in the system is to flush it before them.
commissioning. No additional loading weights must be added.
The lever must not be used for suspending any
If leaks are caused by contamination between parts, e.g. for hanging clothes on.
the sealing surfaces, the safety valve can be
vented to clean the surfaces. If this does not
stop the leak, one of the sealing surfaces is 13 Setting instructions for spring loaded safety
probably damaged. In this case the safety valve valves
has to be serviced.
The following operating instructions only apply
12.12 Protection during storage and transport to valves without additional equipment. If there
All protective devices for transport and handling is additional equipment (such as O-ring
have to be removed before installing the safety dampers, proximity switches, bellows, ...)
valve. please refer to the corrosponding assembly
instructions.
After installation, the protection for the lever
must be removed from the bonnet as otherwise 13.1 Lifting device H3
the safety valve cannot be vented. The lever 1. Remove shaft (40.4).
must move freely, i.e. it must be in its initial 2. Pull lever (40.6) out to the side.
position and the coupling at the spindle must 3. Loosen hexagonal head screw (40.3).
not be connected to the lever. 4. Unscrew and remove lever cover (40.1).
25
5. Loosen lock nut (19). 5. Loosen the lock nut (19) of the adjusting
6. 1) Turn adjusting screw (18) to the required screw (18).
set pressure. 6. 1) Turn the adjusting screw (18) anticlock-
Pay attention to the admissible pressure wise to remove all spring tension.
range of the spring! 7. Remove the hex. nuts (56) from the flange
Clockwise turning of adjusting screw of the bonnet (9).
increase the spring tension, giving a higher 8. Lift off the bonnet (9).
set pressure. 9. Remove the upper spring plate (16).
Anticlockwise turning of adjusting screw 10. Lift off the spring (54) and remove lower
reduces the spring tension, giving a lower set spring plate (16) and split rings (14).
pressure. 11. Remove spindle (12) with guide (8) and
7. Reassemble in reverse order and lock at the disc (7).
E set pressure. 12. Carefully clean seat (5) and disc (7), and if
required body internals.
19 13. Refit spindle (12) with guide (8) and disc (7).
40.4 19
14. Fit the split rings (14) into spindle groove
40.1 and retain with the securing ring (59); slip
40.3
40.3 on lower spring plate (16) to locate on split
18
rings (14).
40.6
40.6
15. Replace spring (54).
16. Slip on the upper spring plate (16) onto the
spindle (12).
17. Align adjusting screw (18), and bonnet (9).
Fig. 1
over the spindle (12) and refit.
18. Fit and tighten the hex. nuts (56).
13.2 Lifting device H4 19. 1) Load the spring (54) to obtain the required
1. Loosen the spring cover (40.1.1) and set pressure. Clockwise rotation of
simultaneously press the lever (40.1.6) in the adjusting screw (18) increases pressure.
direction of the bonnet so that the lifting fork Anticlockwise rotation of adjusting screw
(40.1.5) comes free. (18) reduces pressure.
2. Remove the lever cover (40.1.1). 20. Tighten the lock nut (19) onto the adjusting
3. Loosen the lock nut (19). screw (18).
4. 1) Turn adjusting screw (18) as described in 21. Refit and secure spindle cap (40.12) by pin
lifting device H3. Pay attention to the ad- (40.13) and securing ring (40.14).
missible pressure range of the spring! 22. Screw-on the lever cover (40.1).
5. Reassemble in reverse order and lock at the 23. Pull the lever (40.6) towards the middle so
set pressure. that the lifting fork (40.5) is pushed under
the spindle cap (40.12).
24. Test spindle will lift correctly by pulling
40.1.6
lever.
40.1.5
18 These instructions are applicable for relief valves,
safety valves and safety relief valves.
40.1.1
19 1)Caution: During all work the spindle has to be
secured against twisting in order to prevent
damage to the sealing surfaces.
Fig. 2
13.3 Spring replacement The following points should be noted:

The following items refer to the figures shown in The pressure setting is wire-locked and
the LESER Product Catalogue. sealed against unauthorized alteration. The
rules and standards, agreed by the manu-
1. Loosen the existing lead seal. facturer, require the fitting of a name plate
2. Press the lever (40.6) towards the middle stating the correct valve data. The manu-
until it reaches the stop so that the lifting facturer cannot be held responsible for any
fork (40.5) no longer holds the spindle cap changes to set pressure or other alterations
(40.12). after despatch from the factory. Necessary
3. Loosen and remove the lever cover (40.1). modifications should only be made by
4. Loosen the spindle cap (40.12) from the authorised distributors of LESER or under the
spindle (12), remove the securing ring supervision of the TÜV or any other
(40.14) and the pin (40.13). competent inspection authority.
26
14 Handling 15 Supplementary loading system
There is a risk of injury from sharp edges and Even if the external energy supply (compressed
burrs. For this reason all parts have to be handled air) fails, the direct-loaded safety valve is still fully
with caution. functional. In this case the function is equivalent
to the LESER standard safety valve without
There is a risk from safety valves falling over. supplementary loading system.
They always have to be secured adequately.
The compressed air filter must be serviced at
During dismantling the spring must not be regular intervals as specified in the maintenance
tensioned. Otherwise there is danger of injury instructions.
from flying parts. Observe the assembly
instructions for the relevant safety valves! The installation should contain an air dryer. The E
compressed air should have a dew-point of
Before dismantling you should always check minimum +2 °C.
whether there is, or could be, any medium in the
bonnet; also check what the medium is. The maximum pressure of the air supply is 10
bar, the minimum pressure is 3.5 bar. If the
There is a great risk of injury, chemical burns pressure rises above or falls below the specified
or poisoning if there is any remaining medium interval, this may lead to temporary or permanent
inside the safety valve. failure of the supplementary loading system. As a
result the safety valve does not function or it
One should use conventional high quality tools in will work as a standard valve without the
order to minimise the risks arising from bad supplementary loading system.
quality tools or inadequate tools. Any necessary
special tools are indicated in the assembly The supplementary loading system should be
instructions. serviced and checked at least once a year by
specially trained staff. For this essential work
Safety valves may only be dismantled and LESER offers a maintenance service which may
assembled by skilled staff. be incorporated in a service agreement. Training
The training can be carried out: and experience with handling the supplementary
• In the workshop by experienced staff loading system in combination with the safety
• At LESER training seminars valves are essential.
• By means of LESER documentation, e.g., The supplementary loading system has to be
videos, operating instructions, catalogues, fitted in accordance with the rules and standards
assembly instructions and the specifications distributed by LESER. If
serviced correctly, failures due to contamination
The maintenance staff must be informed about of the pressure and control lines can be ex-
the risks during dismantling and installing the cluded.
safety valves.
The control unit is to be protected from
Contamination and damage to the safety valve contamination. It has to be ensured that it is
must be avoided. Suitable cartons, protective always closed. For special applications LESER
covers for the flanges, wrapping foil, shipping offers an encapsulated box sealing the control
palettes etc. have to be used. The packaging unit.
must be completely removed before installation
as otherwise the function of the safety valve The actuator on the safety valve itself as well as
cannot be guaranteed. sliding parts inside an open bonnet must be
Safety valves have to be handled with care as protected from contamination. Otherwise there is
otherwise the vulnerable sealing surfaces can be the danger of jamming.
damaged or the safety valve might even be
rendered useless. Temperatures:
The controls and actuators are designed for
Safety valves must be stored in a dry place. The applications between 2 °C and 60 °C.
optimum storage temperature is 5 °C to 40 °C. • At temperatures above 60 °C the compressed
For o-ring discs temperatures below freezing air connections must be as long as possible
should be avoided, if possible. The temperature and equipped with a water seal.
resistance, in particular of the o-ring materials, • The control unit and actuators have to be
has to be taken into account. positioned in a way that their temperature will
Upper limit for storage: 50 °C not exceed 60 °C.
Lower limit for storage: -10 °C • At a temperature below 2 °C there may be
danger of icing-up, therefore it may be
necessary to heat control unit, control lines and
tapping lines.
The supplementary loading system is
27
connected to the safety valve via a coupling. The 17 Unexpected conditions

coupling must not be blocked by objects. It is
neither necessary nor permitted to apply a Not all errors can be prevented entirely.
protective coating to the actuator.
However, their consequences must be estimated
The pressure tapping lines must not be shut off. If and reduced by:
there are shut-off devices they have to be • A risk analysis for the complete installation
designed in such a way that they cannot be • An estimate of the risk and potential damage
closed, e.g., by means of locking bars or seals. • Instructions about the measures to be taken in
the case of malfunctioning
LESER control units are equipped with a shut-off • Staff training at the manufacturer’s and at the
device for maintenance purposes. They are operator’s
E secured against shutting-off by means of a • Protective measures for people and for the
locking bar. This locking bar must not be environment.
removed.
The pressure switches are wire-locked and 18 Product overview

sealed. This seal indicates that the setting has
not been changed. It is not permitted to For the product overview please refer to the
manipulate the pressure switches (e.g., by “Declaration of conformity”.
opening the seal and modifying the adjustment or
by opening the switching contacts, ...)!
19 Assembly instructions
If a test gag is used during pressure testing of the
installation it must be removed after the test. In addition to the Operating Instructions there is a
number of type-specific assembly instructions,
which are listed in the “Request form LESER
16 Combined Safety Valve and Bursting Disc Assembly Instructions”.
The type test approval of the combination of In detail the type-specific assembly instructions
bursting discs of a certain manufacturer with have to be observed.
LESER safety valve ensures that both the
functional and performance requirements are
met. If you require information on the tested 20 Disclaimer
combinations, please contact LESER.
The manufacturer reserves the right to make
Combinations of LESER safety valves and technical changes or improvements at any time.
bursting discs of other manufacturers are per-
missible, if they meet the safety requirements.
This shall be certified for each individual case.
The following points should be noted in

particular:
• Operating instructions for the bursting disc.
• Safety valves must not lose their function by
placing the upstream bursting disc.
• The space between the rear side of the bursting
disc and safety valve inlet should be monitored.
• The bursting disc should be designed in a way
that it cannot be installed incorrectly.
• The bursting disc has to open free of
fragments. Bursting disc components must not
enter the inlet connecting pieces of the safety
valve thus impairing the function.
• Sets of rules with reference to bursting discs
(AD 2000-Merkblatt A1, ASME, ...)
28
additional drain pipe

in case of prepared
drainhole
E
incorrect! correct!
Fig. 4 Fig. 3
29
The Safety Valve
Declaration of Conformity/Konformitätserklärung
according to Pressure Equipment Directive 97/23/EC
nach Druckgeräterichtlinie 97/23/EG
LESER GmbH & Co. KG
E Wendenstr. 133-135
20537 Hamburg/Germany
Name and address of the manufacturer/Name und Anschrift des Herstellers
Nominal pipe size/ Nominal pipe size/

Nennweite EC-type examination No./ Nennweite EC-type examination No./
Type* Type*
EG-Bauteilprüfnummer EG-Bauteilprüfnummer
NPS DN NPS DN
411 ¾" - 6" 20 - 150 07 202 0111Z0008/0/02 532, 534 ½" - 6" 20 - 150 07 202 0111Z0008/0/15
421 1"- 4" 25 - 100 07 202 0111Z0008/0/03 538 ½" 10 07 202 0111Z0008/0/16
424 – 25 - 200 07 202 0111Z0008/0/04 539 ½" - ¾" 10 - 15 07 202 0111Z0008/0/17
427, 429 ½" - 6" 15 - 150 07 202 0111Z0008/0/05 543, 544 2" - 4" 50 - 100 07 202 0111Z0008/0/18
431, 433 ½" - 6" 15 - 150 07 202 0111Z0008/0/06 546 1" - 4" 25 - 100 07 202 0111Z0008/0/19
440 – 20 - 150 07 202 0111Z0008/0/07 483, 484, 485 1", 2" 25, 40 07 202 0111Z0008/0/20
441, 442, 444 ¾" - 16" 20 - 400 07 202 0111Z0008/0/08-2 437, 438, 439, 481 ½", ¾", Ǫ" – 07 202 0111Z0008/0/21-2
SVL 606 ¾" - 16" 20 - 400 07 202 0111 Z0008/0/08-2 700 – – 07 202 0111Z0008/0/22
447 1" - 4" 25 - 100 07 202 0111Z0008/0/09 522 2" - 4" 50 - 100 07 202 0111Z0008/0/23
448 1" - 4" 25 - 100 07 202 0111Z0008/0/10 450/460 ¾" - 1" 15 - 20 07 202 0111Z0008/0/24
455, 456 1" - 4" 25 - 100 07 202 0111Z0008/0/11 488 1" - 4" 25 - 100 07 202 0111Z0008/0/25-1
457, 458 1" - 6" 25 - 150 07 202 0111Z0008/0/12 SVL 488 1" - 4" 25 - 100 07 202 0111Z0008/0/25-1
459 ½" - 1" 10 - 20 07 202 0111Z0008/0/13 526 1" - 8" 25 - 200 07 202 1111Z0012/2/26
462 ¾" - 1" 15 - 20 07 202 0111Z0008/0/14 486, 586 1" - 3" 25 - 80
Description of the pressure equipment/Beschreibung des Druckgerätes * See name plate/siehe Bauteilprüfschild
Kategorie IV/Category IV
Applied category according to article 3 and annex II/Angewandte Kategorie nach Artikel 3 und Anhang II
Conformity assessment procedures/ Certificate number/

Module/Modul
Konformitätsbewertungsverfahren Bescheinigungsnummer
B EC type-examination/EG-Baumusterprüfung See table/siehe Tabelle
D/D1 Production quality assurance/Qualitätssicherung Produktion 07 202 0111Z0008/0/01-2
Conformity assessment procedures according to article 10/Angewandte Konformitätsbewertungsverfahren nach Artikel 10
TÜV CERT - Zertifizierungsstelle für Druckgeräte der TÜV NORD GRUPPE

Identification number 0045, Große Bahnstr. 31, 22525 Hamburg/Germany
Name and address of the notified body (monitoring a.m. conformity assessment procedures)
Name und Anschrift der benannten Stelle (Zertifizierung/Überwachung nach o.g. Modulen)
The signing manufacturer confirms by this declaration that the design, manufacturing and inspection of this pressure
equipment meet the requirements of the Pressure Equipment Directive.
Der unterzeichnende Hersteller bescheinigt hiermit, dass Konstruktion, Herstellung und Prüfung dieses Druckgerätes
den Anforderungen der Druckgeräterichtlinie entsprechen.
DIN EN 12516, DIN EN 1503, DIN EN 12953, DIN EN 12266, DIN EN ISO 4126-1, EN 13463-1, EN 13463-5, EN 1127-1
LWN 248.13 -06/04
Applied harmonized standards/Angewandte harmonisierte Normen
AD 2000-Merkblatt A2, AD 2000-Merkblatt A4, TRB 403, TRD 421, TRD 721, DIN 3320, DIN 3840, VdTÜV SV 100
Other applied standards or technical rules/Andere angewandte Normen oder technische Spezifikationen
25.11.2004
Date Manufacturer stamp Authorized subscriber
LESER GmbH & Co. KG Hamburg HRA 82 424 Fon +49 (40) 251 65 - 100 Bank Vereins- und Westbank AG, Hamburg LESER - The Safety Valve
GF · BoD Joachim Klaus, Martin Leser Fax +49 (40) 251 65 - 500 BLZ 200 300 00, Konto · Account 3203171
20537 Hamburg, Wendenstr. 133-135 E-Mail [email protected] SWIFT: VUWBDEHHXXX
20506 Hamburg, P.O. Box 26 16 51( ) Internet www.leser.com IBAN: DE64 2003 0000 0003 2031 71
USt-ID · VAT-Reg DE 118840936
30
The Safety Valve
according to Pressure Equipment Directive 97/23/EC (PED)
nach Druckgeräterichtlinie 97/23/EG (DGR)
Potentially Explosive Atmospheres 94/9/EC (ATEX)
Explosionsgefährdete Bereiche 94/9/EG (ATEX)
LESER GmbH & Co. KG E
Wendenstr. 133-135

EC-type examination No./ EC-type examination No./
Type* Nennweite Type* Nennweite
NPS DN NPS DN
411 ¾" - 6" 20 - 150 07 202 0111Z0008/0/02 538 ½" 10 07 202 0111Z0008/0/16
421 1"- 4" 25 - 100 07 202 0111Z0008/0/03 539 ½" - ¾" 10 - 15 07 202 0111Z0008/0/17
424 – 25 - 200 07 202 0111Z0008/0/04 543, 544 2" - 4" 50 - 100 07 202 0111Z0008/0/18
427, 429 ½" - 6" 15 - 150 07 202 0111Z0008/0/05 546 1" - 4" 25 - 100 07 202 0111Z0008/0/19
431, 433 ½" - 6" 15 - 150 07 202 0111Z0008/0/06 483, 484, 485 1", 2" 25, 40 07 202 0111Z0008/0/20
440 – 20 - 150 07 202 0111Z0008/0/07 437, 438, 439, 481 ½", ¾", Ǫ" – 07 202 0111Z0008/0/21-1
441, 442, 444 ¾" - 16" 20 - 400 07 202 0111Z0008/0/08-2 700 - - 07 202 0111Z0008/0/22
455, 456 1" - 4" 25 - 100 07 202 0111Z0008/0/11 522 2" - 4" 50 - 100 07 202 0111Z0008/0/23
457, 458 1" - 6" 25 - 150 07 202 0111Z0008/0/12 450/460 ¾" - 1" 15 - 20 07 202 0111Z0008/0/24
459 ½" - 1" 10 - 20 07 202 0111Z0008/0/13 488 1" - 4" 25 - 100 07 202 0111Z0008/0/25
462 ¾" - 1" 15 - 20 07 202 0111Z0008/0/14 526 1" - 8" 25 - 200 07 202 1111Z0012/2/26
532, 534 ½" - 6" 20 - 150 07 202 0111Z0008/0/15
Category IV/Kategorie IV (PED/DGR)


Module/Modul

Group II, Category 1, 2 and 3/Gruppe II, Kategorie 1, 2 und 3 (ATEX)

The signing manufacturer declares that in compliance with the Directive 94/9/EC, the products detailed above are suitable
for use as equipment group II categories 1, 2 and 3 and have been manufactured acc. to Annex VIII "Internal control of
production".
Der unterzeichnende Hersteller bestätigt, dass in Übereinstimmung mit der Richtlinie 94/9/EG, die oben aufgeführten
Produkte für die Verwendung als Geräte der Gruppe II, Kategorien 1, 2 und 3 geeignet sind und entsprechend
Anhang VIII "Interne Fertigungskontrolle" hergestellt wurden.
LWN 248.21 -06/2004
June 30, 2004

Date/Datum Manufacturer stamp/Herstellerstempel Authorized subscriber/Authorisierter Unterzeichner
31
The Safety Valve
E LESER GmbH & Co. KG

Wendenstr. 133-135
Applied category in Conformity assessment

Nominal Description of
acc. to article 3 and procedures according to CE-
pipe pressure
Material/ annex II/ article 10/ marking/
Type* size/ equipment/
Werkstoff Angewandte Kategorie Angewandte Konformitäts- CE-Kenn-
Nenn- Benennung des
nach Artikel 3 und bewertungsverfahren nach zeichnung
weite DN Druckgerätes
Anhang II Artikel 10
Art. 3 Par. 3 Not necessary No
0.6025 15-50
Art. 3 Abs. 3 Nicht erforderlich Nein
GG-25/
GJL-250 Kat. I Yes
65-100 A
Pressure Reducer Cat. I Ja
612
Druckminderer Art. 3 Par. 3 Not necessary No
1.0619 15-32
GS-C 25/
GP 240 GH Kat. I Yes
40-100 A
Cat. I Ja

Module/Modul
D1 Production quality assurance/Qualitätssicherung Produktion 07 202 0111Z0008/0/01-2
Certificate number of module D1/Zertifikatsnummer Modul D1

Identification number: 0045, Große Bahnstr. 31, 22525 Hamburg/Germany
The signing manufacturer confirms by this declaration that the design, manufacturing and inspection of this
pressure equipment meet the requirements of the Pressure Equipment Directive.
Der unterzeichnende Hersteller bescheinigt hiermit, dass Konstruktion, Herstellung und Prüfung dieses
Druckgerätes den Anforderungen der Druckgeräterichtlinie entsprechen.
DIN EN 1503-1, DIN EN 1503-3, DIN EN 10213-1, DIN EN 10213-2

DIN 3840, DIN 1691, DIN EN 1561

LWN 248.14 -06/04
30.06.2004
32
10. Messtechnik
10. Measurement

Commission-N°:
7001021687
Factory-N°:
4020004 Project:
TIMOR 1
Drawing-N°:
BB2285A
Baujahr: Pos.-Nr.:

14 Pressure Measurement
14,1 11MAM60CP510 1 WIKA 233.50.100 1/2" NPT Body: 316L -- pressure gauge
Commission-No.:
Customer:

Factory-No.:
4020004 TIMOR 1
Project:
Drawing-No.:
67-3265 BB285A
Project-No.:
Baujahr: Pos.-Nr.:
2021 --
Pos.-No.:
Pos. 14 Pressure
11MAM60CP510
Bourdon tube pressure gauge, stainless steel
For the process industry, standard version
Models 232.50, 233.50, NS 63 [2 ½"], 100 [4"] and 160 [6"]
WIKA data sheet PM 02.02
for further approvals

see page 5
Applications
■ For gaseous and liquid aggressive media that are
not highly viscous or crystallising, also in aggressive
environments
■ Chemical and petrochemical industries, oil and gas indus-
try, power engineering and also water and wastewater
technology
■ Machine building and general plant construction
Special features
■ Excellent load-cycle stability and shock resistance
■ With case filling (model 233.50) for applications with high
dynamic pressure loads and vibrations
■ Completely from stainless steel
■ Scale ranges from 0 … 0.6 to 0 … 1,600 bar
[0 ... 10 to 0 ... 20,000 psi] Bourdon tube pressure gauge, model 232.50,
NS 100 [4"]
Description
This high-quality Bourdon tube pressure gauge has been WIKA manufactures and qualifies the pressure gauge
designed especially for the process industry. in accordance with the standards EN 837-1 and
ASME B40.100. This instrument has as safety function a
The use of high-quality stainless steel materials and the blow-out device with blow-out plug on the back of the case. In
robust design are geared to applications in the chemical the event of a failure, overpressure can escape there.
and process engineering industries. Thus the instrument is
suitable for liquid and gaseous media, also in aggressive The model 233.50 with liquid-filled case is suitable for high
environments. dynamic pressure loads and vibrations.
Scale ranges of 0 … 0.6 to 0 … 1,600 bar [0 ... 10 to

0 ... 20,000 psi] ensure the measuring ranges required for a
wide variety of applications.
WIKA data sheet PM 02.02 ∙ 01/2021 Page 1 of 11
Data sheets showing similar products:

Stainless steel, safety version; model 232.30; see data sheet PM 02.04
Bourdon tube pressure gauge with switch contacts; models PGS23.100 and PGS23.160; see data sheet PV 22.02
Pressure gauge per EN 837-1 with mounted diaphragm seal; model DSS27M; see data sheet DS 95.12
Specifications
Basic information
Standard ■ EN 837-1
■ ASME B40.100
For information on the “Selection, installation, handling and operation of pressure

gauges”, see Technical information IN 00.05.
Nominal size (NS) ■ Ø 63 mm [2 ½"]
■ Ø 100 mm [4"]
■ Ø 160 mm [6"]
Window Laminated safety glass (NS 63 [2 ½"]: Polycarbonate)

Case
Design Safety level “S1” per EN 837-1
With blow-out device at case circumference, 12 o‘clock (NS 63 [2 ½"]) and on the
back of the case (NS 100 [4"] and 160 [6"])
Scale ranges ≤ 0 ... 16 bar [≤ 0 ... 300 psi] with compensating valve to vent and
reseal case
Material ■ Stainless steel 1.4301 (304)
■ Stainless steel 1.4571 (316 Ti)
Ring Bayonet ring, stainless steel

Mounting ■ Without
■ Panel mounting flange, stainless steel
■ Panel mounting flange, polished stainless steel
■ Triangular profile ring, stainless steel polished with mounting bracket
■ Surface mounting flange, stainless steel
Case filling (model 233.50) ■ Without
■ Glycerine
■ Glycerine-water mixture for NS 100 [4“] and 160 [6“] with scale range
≤ 0 ... 2.5 bar [≤ 0 ... 40 psi] or for NS 63 [2 ½“] with scale range ≤ 0 ... 4 bar
[≤ 0 ... 60 psi]
■ Silicone oil
Movement ■ Stainless steel

■ everlast® design
Measuring element
Type of measuring element Bourdon tube, C-type or helical type
Material ■ Stainless steel 1.4404 (316L)
■ Monel (models 262.50 and 263.50)
Leak tightness ■ Helium tested, leakage rate: < 5∙10-3 mbar l/s
■ Helium tested, leakage rate: < 1∙10-6 mbar l/s
Accuracy specifications
Accuracy class
NS 63 [2 ½"] ■ EN 837-1 Class 1.6
■ ASME B40.100 ±2 ½ % of measuring span (grade A)
NS 100 [4"], 160 [6"] ■ EN 837-1 Class 1,0
■ ASME B40.100 ±1.0 % of measuring span (grade 1A)
Temperature error On deviation from the reference conditions at the measuring system:
≤ ±0.4 % per 10 °C [≤ ±0.4 % per 18 °F] of full scale value
Reference conditions
Ambient temperature +20 °C [68 °F]

Scale ranges
Scale range Scale range

bar kg/cm2 psi psi
0 ... 0.6 1) 0 ... 0.6 1) 0 ... 10 1) 0 ... 1,000
0 ... 1 0 ... 1 0 ... 15 0 ... 1,500
0 ... 1.6 0 ... 1.6 0 ... 30 0 ... 2,000
0 ... 2.5 0 ... 2.5 0 ... 60 0 ... 3,000
0 ... 4 0 ... 4 0 ... 100 0 ... 4,000
0 ... 6 0 ... 6 0 ... 160 0 ... 5,000
0 ... 10 0 ... 10 0 ... 200 0 ... 6,000
0 ... 16 0 ... 16 0 ... 300 0 ... 7,500
0 ... 25 0 ... 25 0 ... 400 0 ... 10,000
0 ... 40 0 ... 40 0 ... 600 0 ... 20,000
0 ... 60 0 ... 60 0 ... 800
0 ... 100 0 ... 100
0 ... 160 0 ... 160
0 ... 250 0 ... 250 Vacuum and +/- scale ranges
0 ... 400 0 ... 400 Scale range
0 ... 600 0 ... 600 bar MPa
0 ... 1,000 0 ... 1,000 -0.6 ... 0 1) -0.06 ... 0 1)
0 ... 1,600 0 ... 1,600 -1 ... 0 -0.1 ... 0
kPa MPa -1 ... +0.6 -0.1 ... +0.06
0 ... 60 1) 0 ... 0.06 1) -1 ... +1.5 -0.1 ... +0.15
0 ... 100 0 ... 0.1 -1 ... +3 -0.1 ... +0.3
0 ... 160 0 ... 0.16 -1 ... +5 -0.1 ... +0.5
0 ... 250 0 ... 0.25 -1 ... +9 -0.1 ... +0.9
0 ... 400 0 ... 0.4 -1 ... +15 -0.1 ... +1.5
0 ... 600 0 ... 0.6 -1 ... +24 -0.1 ... +2.4
0 ... 1,000 0 ... 1 kPa psi
0 ... 1,600 0 ... 1.6 -60 ... 0 1) -30 inHg ... 0
0 ... 250 0 ... 2.5 -100 ... 0 -30 inHg ... +15
0 ... 400 0 ... 4 -100 ... +60 -30 inHg ... +30
0 ... 600 0 ... 6 -100 ... +150 -30 inHg ... +60
0 ... 1,000 0 ... 10 -100 ... +300 -30 inHg ... +100
0 ... 1,600 0 ... 16 -100 ... +500 -30 inHg ... +160
0 ... 2,500 0 ... 25 -100 ... +900 -30 inHg ... +200
0 ... 4,000 0 ... 40 -100 ... +1,500 -30 inHg ... +300
0 ... 6,000 0 ... 60 -100 ... +2,400
0 ... 10,000 0 ... 100
0 ... 16,000 0 ... 160
1) Not available for NS 63 [2 ½"]
Further information on: Scale ranges

Special scale ranges Other scale ranges on request
Unit ■ bar
■ psi
■ kg/cm²
■ kPa
■ MPa

Increased overload safety ■ Without
■ 2 times
■ 3 times
■ 4 times
■ 5 times
The possibility of selection depends on scale range and nominal size
Vacuum resistance ■ Without
■ Vacuum-resistant to -1 bar
Dial
Scale colour Black
Material Aluminium
Special scale ■ Without
■ With temperature scale for refrigerant, e.g. for NH3: R 717
Other scales or customer-specific dials, e.g. with red mark, circular arcs or circular
sectors, on request
Pointer
Instrument pointer Aluminium, black
Mark pointer/drag pointer ■ Without
■ Red mark pointer on dial, fixed
■ Red mark pointer on window, adjustable
■ Mark pointer on bayonet ring, adjustable
■ Red drag pointer on window, adjustable
Pointer stop pin ■ Without
■ At the zero point (only for NS 63 [2 ½"])
■ At 6 o‘clock (only for NS 100 [4"], 160 [6"])
Process connections
■ ISO 7
■ ANSI/B1.20.1
Size
EN 837-1 ■ G ⅛ B, male thread
■ G ¼ B, male thread
■ G ½ B, male thread
■ M12 x 1.5, male thread
ISO 7 ■ R ¼, male thread
■ R ½, male thread
ANSI/B1.20.1 ■ ¼ NPT, male thread

■ ½ NPT, male thread
Restrictor ■ Without
■ ∅ 0,6 mm [0,024"], stainless steel
Materials (wetted)
Process connection ■ NS 100 [4"], 160 [6"]: Stainless steel 1.4404 (316L)
■ NS 63 [2 ½"]: Stainless steel 1.4571 (316 Ti)
Bourdon tube ■ Stainless steel 1.4404 (316L)

Other process connections on request

Operating conditions
Medium temperature
Unfilled instruments -40 ... +200 °C [-40 ... +392 °F]
Instruments with glycerine filling -20 ... +100 °C [-4 ... +212 °F]
Instruments with silicone oil filling -40 ... +100 °C [-40 ... +212 °F]
Ambient temperature
Unfilled instruments or with silicone oil filling -40 ... +60 °C [-40 ... +140 °F]
Pressure limitation
NS 63 [2 ½"] Steady 3/4 x full scale value
Fluctuating 2/3 x full scale value
Short time Full scale value
NS 100 [4"], 160 [6"] Steady Full scale value
Fluctuating 0.9 x full scale value
Short time 1.3 x full scale value
Ingress protection per IEC/EN 60529 ■ IP65
■ IP66 (only selectable for scale ranges from 0 ... 20 bar [ 0 ... 400 psi])

Approvals
Approvals included in the scope of delivery

Logo Description Country
EU declaration of conformity European Union
Pressure equipment directive
PS > 200 bar, module A, pressure accessory
- CRN Canada
Safety (e.g. electr. safety, overpressure, ...)
For scale ranges ≤ 1,000 bar
Optional approvals
ATEX directive
Hazardous areas
- Ex h Gas II 2G Ex h IIC T6 ... T1 Gb X
Dust II 2D Ex h IIIC T85°C ... T450°C Db X
EAC Eurasian Economic Community

Hazardous areas
GOST Russia
Metrology, measurement technology
KazInMetr Kazakhstan
- MTSCHS Kazakhstan
Permission for commissioning
BelGIM Belarus
UkrSEPRO Ukraine
Uzstandard Uzbekistan
- CPA China
DNV GL International
Ships, shipbuilding (e.g. offshore)
Certificates (option)
Certificates
Certificates ■ 2.2 test report per EN 10204 (e.g. state-of-the-art manufacturing, indication accuracy)
■ 3.1 inspection certificate per EN 10204 (e.g. material proof for wetted metal parts, indication accuracy)
■ PCA calibration certificate, traceable and accredited in accordance with ISO/IEC 17025
■ Calibration certificate by the national accreditation body, traceable and accredited in accordance with
ISO/IEC 17025 on request
Recommended 1 year (dependent on conditions of use)
recalibration interval
→ Approvals and certificates, see website

Dimensions in mm [in]
Lower mount (radial)
b
j
≤ 16 bar [≤ 300 psi] with vent valve
> 16 bar [> 300 psi] without vent valve
Øk
ØD1
ØD2 NS Weight
h
SW Model 232.50 Model 233.50
14311051.01
63 [2 ½"] approx. 0.16 kg [0.35 lbs] approx. 0.20 kg [0.44 lbs]
G G
100 [4"] approx. 0.6 kg [1.32 lbs] approx. 0.9 kg [1.98 lbs]
ISO ANSI a 160 [6"] approx. 1.1 kg [2.43 lbs] approx. 2.0 kg [4.41 lbs]
Process connection with thread per EN 837-1

NS G Dimensions in mm [in]
h ±1 a b D1 D2 i y k SW
63 [2 ½"] G¼B 54 [2.13] 9.5 [0.37] 33 [1.30] 63 [2.48] 62 [2.44] 6 [0.24] 10 [0.39] 15 [0.59] 14 [0.55]
G⅛B 51 [2.01]
M12 x 1.5 54 [2.13]
100 [4"] G¼B 80 [3.15] 15.5 [0.61] 49.5 [1.95] 101 [3.98] 99 [3.90] 6.5 [0.26] 14.5 [0.57] 22.5 [0.89] 22 [0.87]
G½B 87 [3.43]
M12 x 1.5 80 [3.15]
M20 x 1.5 87 [3.43]
160 [6"] G¼B 111 [4.37] 15.5 [0.61] 49.5 [1.95] 1) 161 [6.34] 159 [6.26] 6.5 [0.26] 14.5 [0.57] 22.5 [0.89] 22 [0.87]
G½B 118 [4.65]
M12 x 1.5 111 [4.37]
M20 x 1.5 118 [4.65]
Process connection with thread per ISO 7

63 [2 ½"] R¼ 54 [2.13] 9.5 [0.37] 33 [1.30] 63 [2.48] 62 [2.44] 6 [0.24] 10 [0.39] 15 [0.59] 14 [0.55]
100 [4"] R¼ 80 [3.15] 15.5 [0.61] 49.5 [1.95] 101 [3.98] 99 [3.90] 6.5 [0.26] 14.5 [0.57] 22.5 [0.89] 22 [0.87]
R½ 86 [3.39]
160 [6"] R¼ 111 [4.37] 15.5 [0.61] 49.5 [1.95] 1) 161 [6.34] 159 [6.26] 6.5 [0.26] 14.5 [0.57] 22.5 [0.89] 22 [0.87]
R½ 117 [4.60]
Process connection with thread per ANSI/B1.20.1

63 [2 ½"] ¼ NPT 54 [2.13] 9.5 [0.37] 33 [1.30] 63 [2.48] 62 [2.44] 6 [0.24] 10 [0.39] 15 [0.59] 14 [0.55]
⅛ NPT 51 [2.01]
100 [4"] ¼ NPT 80 [3.15] 15.5 [0.61] 49.5 [1.95] 101 [3.98] 99 [3.90] 6.5 [0.26] 14.5 [0.57] 22.5 [0.89] 22 [0.87]
½ NPT 86 [3.39]
160 [6"] ¼ NPT 111 [4.37] 15.5 [0.61] 49.5 [1.95] 1) 161 [6.34] 159 [6.26] 6.5 [0.26] 14.5 [0.57] 22.5 [0.89] 22 [0.87]
½ NPT 117 [4.60]
1) Plus 16 mm [0.630 in] with scale range 0 ... 1,600 bar [0 ... 20,000 psi]

Lower back mount
b
j
i
Øk
ØD1
SW
ØD2
e
ISO
G
NS Weight
Model 232.50 Model 233.50
ANSI

G
1431111.01
h1 100 [4"] approx. 0.6 kg [1.32 lbs] approx. 0.9 kg [1.98 lbs]

h ±1 b D1 D2 e i y k SW
63 [2 ½"] G¼B 57 [2.24] 33 [1.30] 63 [2.48] 62 [2.44] 18.5 [0.73] 6 [0.24] 10 [0.39] 15 [0.59] 14 [0.55]
G⅛B 54 [2.13]
M12 x 1.5 57 [2.24]
100 [4"] G¼B 76 [2.99] 49.5 [1.95] 101 [3.98] 99 [3.90] 30 [1.18] 6.5 [0.26] 14.5 [0.57] 22.5 [0.89] 22 [0.87]
G½B 83 [3.27]
M12 x 1.5 76 [2.99]
M20 x 1.5 83 [3.27]
160 [6"] G¼B 76 [2.99] 2) 49.5 [1.95] 1) 161 [6.34] 159 [6.26] 50 [1.97] 6.5 [0.26] 14.5 [0.57] 22.5 [0.89] 22 [0.87]
G½B 83 [3.27] 2)
M12 x 1.5 76 [2.99] 2)
M20 x 1.5 83 [3.27] 2)

63 [2 ½"] R¼ 57 [2.24] 33 [1.30] 63 [2.48] 62 [2.44] 18.5 [0.73] 6 [0.24] 10 [0.39] 15 [0.59] 14 [0.55]
100 [4"] R¼ 76 [2.99] 49.5 [1.95] 101 [3.98] 99 [3.90] 30 [1.181] 6.5 [0.26] 14.5 [0.57] 22.5 [0.89] 22 [0.87]
R½ 82 [3.23]
160 [6"] R¼ 76 [2.99] 2) 49.5 [1.95] 1) 161 [6.34] 159 [6.26] 50 [1.97] 6.5 [0.26] 14.5 [0.57] 22.5 [0.89] 22 [0.87]
R½ 82 [3.23] 2)

63 [2 ½"] ¼ NPT 54 [2.13] 33 [1.30] 63 [2.48] 62 [2.44] 50 [1.97] 6 [0.24] 10 [0.39] 15 [0.59] 14 [0.55]
⅛ NPT 51 [2.01]
100 [4"] ¼ NPT 80 [3.15] 49.5 [1.95] 101 [3.98] 99 [3.90] 50 [1.97] 6.5 [0.26] 14.5 [0.57] 22.5 [0.89] 22 [0.87]
½ NPT 86 [3.39]
160 [6"] ¼ NPT 76 [2.99] 2) 49.5 [1.95] 1) 161 [6.34] 159 [6.26] 50 [1.97] 6.5 [0.26] 14.5 [0.57] 22.5 [0.89] 22 [0.87]
½ NPT 82 [3.23] 2)
2) Plus 16 mm [0.630 in] with scale ranges ≥ 0 ... 100 bar [≥ 0 ... 1,500 psi]

NS 63 [2 ½"], centre back mount
b
≤ 16 bar [≤ 300 psi] with vent valve j
> 16 bar [> 300 psi] without vent valve Øk
i
SW
ISO
ØD1
ØD2
G
ANSI
G
h1
NS Weight
14112247.01
63 [2 ½“] approx. 0.16 kg [0.35 lbs] approx. 0.20 kg [0.44 lbs]

h ±1 b D1 D2 i y k SW
63 [2 ½"] G¼B 57 [2.24] 33 [1.30] 63 [2.48] 62 [2.44] 6 [0.24] 10 [0.39] 15 [0.59] 14 [0.55]
G⅛B 54 [2.13]
M12 x 1.5 57 [2.24]

63 [2 ½"] R¼ 57 [2.24] 33 [1.30] 63 [2.48] 62 [2.44] 6 [0.24] 10 [0.39] 15 [0.59] 14 [0.55]

63 [2 ½"] ¼ NPT 57 [2.24] 33 [1.30] 63 [2.48] 62 [2.44] 6 [0.24] 10 [0.39] 15 [0.59] 14 [0.55]
⅛ NPT 54 [2.13]

Accessories
Panel mounting flange Surface mounting flange
Ød2 Ød2
Ød1 Ød1
°
°
120
120
120
120
°
°
Ød3
Ød3
NS Dimensions in mm [in]
Recommended panel cutout d1 d2 d3
63 [2 ½"] ∅ 67 ±0.3 / ∅ 2.6 [∅ 2.64 ±0.01 / ∅ 0.10] 75 [2.95] 85 [3.35] 3.6 [0.14]
100 [4"] ∅ 104 ±0.5 / ∅ 4.1 [∅ 4.04 ±0.02 / ∅ 0.16] 117 [4.61] 132 [5.20] 4.8 [0.19]
160 [6"] ∅ 164 ±0.5 / ∅ 6.5 [∅ 6.46 ±0.02 / ∅ 0.26] 178 [7.01] 196 [7.71] 5.8 [0.23]
Triangular profile ring

max. 9
Recommended panel d4
Ød4
cutout
63 [2 ½"] ∅ 64.5 ±0.5 / ∅ 2.5 ≤ 69 [2.72]
[∅ 2.54 ±0.02 / ∅ 0.01]
NS 100 [4"] ∅ 102 ±1.0 / ∅ 4.0 ≤ 108 [4.25]
[∅ 4.02 ±0.04 / ∅ 0.16]
NS 160 [6"] ∅ 162.6 ±1.0 / ∅ 6.4 ≤ 168 [6.61]
[∅ 6.40 ±0.04 / ∅ 0.25]

Accessories and spare parts
Model Description
910.17 Sealings
→ see data sheet AC 09.08
910.15 Syphons
910.13 Overpressure protector

IV10, IV11 Needle valve and multiport valve

IV20, IV21 Block-and-bleed valve

IVM Monoflange, process and instrument version

BV Ball valve, process and instrument version

IBF2, IBF3 Monoblock with flange connection

Ordering information
Model / Nominal size / Scale range / Process connection / Connection location / Options
© 02/1995 WIKA Alexander Wiegand SE & Co. KG, all rights reserved.
The specifications given in this document represent the state of engineering at the time of publishing.
We reserve the right to make modifications to the specifications and materials.
01/2021 EN
WIKA Alexander Wiegand SE & Co. KG

Alexander-Wiegand-Straße 30
63911 Klingenberg/Germany
Tel. +49 9372 132-0
Fax +49 9372 132-406
[email protected]
www.wika.de
Operating 1. Safety gauge, it must be protected against being blocked
instructions EN WARNING!
by debris and dirt. With safety pressure gauges
(see k) there must be a free space of > 15 mm
Before installation, commissioning and
behind the blow-out back.
operation, ensure that the appropriate
After installation, open the vent valve (if available)
Pressure gauges pressure gauge has been selected in
or set from CLOSE to OPEN. With
terms of measuring range, design and
models 4 and 7, do not open the
suitable wetted material (corrosion) for the specific
flange mounting screws. The version
measuring conditions. In order to guarantee the
of the vent valve depends on the
measurement accuracy and long-term stability
Examples: model and can deviate from the above illustration!
specified, the corresponding load limits must be
observed. Requirements for the installation point
Only qualified persons authorised by the plant If the line to the measuring instrument is not
manager are permitted to install, maintain and adequately stable, a measuring instrument holder
service the pressure gauges. should be used for fastening (and possibly via a
Model 732.14, flexible capillary). If vibrations cannot be avoided
For hazardous media such as oxygen, acetylene,
overpressure safety by means of suitable installation, instruments
flammable or toxic gases or liquids, and refrigera-
up to 400 bar with liquid filling should be used. The instruments
tion plants, compressors, etc., in addition to all
Model 432.56, should be protected against coarse dirt and wide
standard regulations, the appropriate existing
overpressure safety fluctuations in ambient temperature.
codes or regulations must also be followed.
up to 100 bar Note for model 732.14, for front bezel mounting:
From pressure gauges which do not correspond The front bezel serves as centring and as the
Model 213.40 to a safety version per EN 837 highly pressurised aperture in the mounting panel. Securing and thus
media might leak out through the possibly burst- the weight-bearing must be made via the pressure
ing window in case of a component failure. For connection piping.
gaseous media and working pressures > 25 bar a
pressure gauge with safety version S3 is recom- 3. Permissible ambient and operating
mended per EN 837-2. temperatures
After an external fire, pressure media can leak out, When mounting the pressure gauge it must be
Notes per current pressure equipment directive particularly at soft solder joints. All instruments ensured that, taking into consideration the influ-
The pressure gauges are defined as “pressure must be checked and, if necessary, replaced ence of convection and heat radiation, no deviation
accessories” before recommissioning the plant. above or below the permissible temperature limits
The volume of the “pressure-bearing housings” of can occur. Observe the influence of temperature
Non-observance of the respective regulations on the indication accuracy!
WIKA pressure gauges is < 0.1 L
can cause serious injuries and/or damage to the
The pressure gauges carry CE marking for fluid
equipment. 4. Storage
group 1 per annex II, diagram 1 when their permis-
sible working pressure is > 200 bar 2. Mechanical connection To protect the pressure gauges from mechanical
damage keep them in the original packaging until
Instruments that do not carry the mark are manufactured In accordance with the general technical regula- installation.
per article 4, paragraph 3 “sound engineering practice”. tions for pressure gauges (e.g. EN 837-2). When Protect the measuring instruments from humidity
screwing the instruments in, the force required to and dust.
Applicable standards (depending on model) do this must not be applied through the case, but Storage temperature range: -40 ... +70 °C
EN 837-1 Bourdon tube pressure gauges, dimensions, only through the spanner flats provided for this Storage temperature range model
metrology, requirements and testing purpose, and using a suitable tool. PG23LT: -70 ... +70 °C
EN 837-2 Selection and installation recommendations For parallel threads, use flat gaskets, lens-type
for pressure gauges sealing rings or WIKA profile sealings at the 5. Maintenance and repairs
EN 837-3 Diaphragm and capsule pressure gauges, The pressure gauges are maintenance-free.
dimensions, metrology, requirements and Regular checks should be carried out to ensure
testing Installation with the measurement accuracy. Checks or recalibra-
Specifications: See data sheet at www.wika.de open-ended tions must only be carried out by qualified skilled
spanner personnel with the appropriate equipment. When
Subject to technical modifications. dismounting, close the vent valve (if available).
© WIKA Alexander Wiegand SE & Co. KG 2009 Sealing of the pressure gauge connections
WARNING! Residual media in
Sealing in dismounted pressure gauges can
Spanner flats the thread result in a risk to persons, the environ-
 ment and equipment. Take sufficient
Sealing face  precautionary measures.
sealing face . With tapered threads (e.g. NPT
WIKA Alexander Wiegand SE & Co. KG threads), sealing is made in the threads  using
Alexander-Wiegand-Straße 30 additional sealing materials, e.g. PTFE tape
2408976.06 12/2016
63911 Klingenberg/Germany (EN 837-2).

Tel. +49 9372 132-0 The torque depends on the sealing used. In order
Fax +49 9372 132-406 to orientate the measuring instrument so that it
[email protected] can be read as well as possible, a connection with
www.wika.de clamp socket or union nut should be used.
When a blow-out device is fitted to a pressure
Betriebsdokumentation
Operating Documentation
Commission-N°:
7001021687
Factory-N°:
4020005 Project:
TIMOR 2
Drawing-N°:
BB2285B
Baujahr: Pos.-Nr.:
2021 Pos.-N°.:
--
ANA
ANA Prozesstechnik GmbH
Herrfurthstraße 9 • D - 06217 Merseburg

Tel.: (03461) 457-0
Fax: (03461) 457-200
eMail: [email protected]
www.ana-gmbh.com
Inhaltsverzeichnis
List of contents

Commission-N°:
7001021687
Factory-N°:
4020005 Project:
TIMOR 2
Drawing-N°:
BB2285B
Baujahr: Pos.-Nr.:
2021 Pos.-N°.:
--
Zeichnung 67-3265
1.
Drawing 67-3265
Betriebsanleitung
2.
Operation Manual
Fließbild
3.
Flow sheet
Montageanleitung und Sicherheitshinweise
4.
Installation- and safety instructions
Lagerungshinweise
5.
Storage instructions
6.
Gland Steam Condenser
Radial-Ventilator
7.
Radial Fan
Armaturen
8.
Valves
Sicherheitsventile
9.
Safety Valves
Messtechnik
10.
Measurement
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24
Vorschriften:
Abnahme:
2 SECTION A-A 2
2 Firmenschild / name plate Inspection by
SECTION B-B DESIGNER: ANA Prozesstechnik GmbH

Rohrraum
A MADE IN GERMANY
MANUFACTURER: AEL Apparatebau GmbH Mantelraum
2 657
Hersteller/ Manufacturer max. zul. Druck
min. / max. FV / 0,5 0 / 27,05 bar Ü
bar g
A
ANA PROZESSTECHNIK GmbH
12 MAM65AA005 Herrfurthstraße 9
06217 Merseburg
max. zul. Temperatur
Allowable working temperature TS
min. / max. 5 / 325 5 / 60 °C
328.5 328.5 AEL APPARATEBAU GmbH
Verfahrensdruck bar Ü
ANA-Kommission
ANA-Commission F220-3512 Operating pressure -0,01...0,0 15,19...15,28 bar g
210 803 Verfahrenstemperatur 67,2...237,2
12 MAM65/02 Operating temperature
40,8...41,8 °C
Prüfüberdruck mit Wasser 20°C - Lage horizontal 3,0 36,5
Benennung bar Ü
Designation
GLAND STEAM CONDENSER MODULE testing pressure with water 20°C - horicontal position PT
bar g
mit Luft (Leckagetest)
B N/A N/A
N3 with air (leakage test)
12 MAM65AA520 12 MAM65AA510 AEL-Fabrik-Nr. Baujahr

Inhalt gesamt 70,0 12,0 l B
AEL-Serial No. 4020005 2021 volume total
Year built
Wärmeaustauschfläche 2
Heat exchanging area 1,37 m
600
Zeichnung-Nr. Leergewicht Fabrik-Nr.
Drawing No. 67-3266 Empty weight 610 kg Factory-No. 4020005
425
Baujahr
2021
12 MAM65AN120 Year of construction
Medium Luft, Dampf Kühlkondensat
air, steam cooling condensate
12 MAM60CP510 12 MAM65AN110 medium
gasförmig flüssig
Bei Ersatzteilbestellung Fabrik-Nr.und Baujahr angeben.
Aggregatzustand
C Dichte 0,53...980 3
992...993
12 LCA10AA310
kg/m
density
C
12 LCA10/03
toxisch / brennbar / explosiv nein / no nein / no
1588
1370 [1375]
Fluidgruppe -- --
416 N4 Fluid group
2 75 75 Schweissnahtfaktor
Firmenschild Kondensator / name plate condenser Korrosionszuschlag

Längsnähte
N6 12 LCA10/01
945
945
Röntgen / U.S.-Pruefung
12 LCA10/02 Long. welds
145 56
D N6 MADE IN GERMANY der Schweissnähte Rundnähte
FS Circ. welds
Hersteller/ Manufacturer X-ray / ultrasonic testing
of welds T-Stoesse D
ANA PROZESSTECHNIK GmbH T-joint
N2 N1 Herrfurthstraße 9
549
06217 Merseburg Andere Prüfungen siehe Schweiß- und

ANA-Kommission AEL APPARATEBAU GmbH Other tests
ANA-Commission F220-3512-002 Prüfplan
350
Benennung in acc. to test plan
300
300
12 LCA10AA/04 Designation gland steam condenser - 12 MAM60AC010 Schweissverfahren
N7 geltende Normen
Welding process
PF. EL. 5000 N7 N7 Die Rohrleitung ist während des Transports demontiert. PF. EL. 5000 applicable norm
AEL-Fabrik-Nr.
AEL-Serial No.
301 543 ; 3120003
Baujahr
Year built 2021
Vorwärmung ja/nein
E The Piping is seperate during transport. min./max. zulässiger Druck
Mantelseite / shell side Rohrseite / tube side Pre-Heating yes/no
95 150 min./max. allowed pressure
[PS] FV / 0,5 bar g 0 / 27,05 bar g Wärmebehandlung ja/nein
12 LCA10AA/05
min./max. zulässige Temperatur

[TS] 5 / 325 °C 5 / 60 °C
Heat treatment
yes/no
E
170 170 Prüfdruck [PT] on site mm
403
Test pressure 3,0 bar g 36,5 bar g Insulation warm/cold

12 MAM60AA010 Inhalt [V]
15,0 l 7,6 l Auskleidung
Volume -- mm
459 Leergewicht Betriebsgewicht
Lining
12 MAM60AA020 Empty weight Operating weight Oberflächenausführung aussen gemäß ANA Anstrichkonzept
N5 100 kg 115 kg
Surface finish outside
12 MAM60AA030 Prüfdatum Monat/Jahr
Test date Month/Year acc. to ANA painting concept
12 MAM60/08 Bei Ersatzteilbestellung Fabrik-Nr.und Baujahr angeben.
F
hinter der Flanschverbindung gehaltert
Gewicht
610 kg
12 MAM60/01

Weight
N8 Gewicht mit Wasserfüllung F
Connecting pipe must be supported
hinter der Flanschverbindung gehaltert werden! Weight full with water 692 kg
1447
Connecting pipe must be supported Bemerkungen Allgemeintoleranzen: für Schweißkonstruktionen - EN ISO 13920 Klasse-B+F ; Lastspiele ≤ 500 ( gem. ASME Sec.VIII );
1507
Remarks
Sicherheitsventil (Rohrraum) Einstelldruck 27,05 barg
12 MAM60/03
12 MAM65/01 general allowances: for welding construction - EN ISO 13920 class-B+F; load application ≤ 500 ( acc. to ASME Sec.VIII ),
Safety valve (tube side) setting pressure 27,05 barg
1000
Die Armatureneinheit ist während des Transports demontiert.

12 MAM65/03
The valve unit is seperate during transport. 2 STUTZENTABELLE / TABLE OF NOZZLES
750
G Bez. TAG Anz. Benennung DN Standard Dichtfläche Rohrabmessung Bemerkung Material
designation class gasket surf.
des. No. no. NPS standard dimens. of tubes remarks material G
Kondensateintritt cooling Typ WN
N1 12 LCA10 01 1 3" 300 ASME B16.5 RF Ø88,9 SA-105
werden!
condensate inlet
Die Rohrleitung ist während des Transports demontiert. 2 ISOMETRIC VIEW Kondensataustritt cooling
The Piping is seperate during transport. N2 12 LCA10 02 1 3" 300 ASME B16.5 RF Ø88,9 Typ WN SA-105
condensate outlet
Abluft vom Gebläse Typ WN
N3 12 MAM65 02 1 3" 150 ASME B16.5 RF Ø88,9 SA-105
H
5 exhaust ait from fans
N9 Dampfeintritt steam
N9
9 9 4 N4 1
inlet
3" 150 ASME B16.5 RF Ø88,9 Typ WN SA-105 H
230 Abfluss des
Abdampfkondensators Typ WN
416 2 573 [580] N5 12 MAM60 01 1 3" 150 ASME B16.5 RF Ø88,9 SA-105
waste steam condenser hotwell
drain
11 N6
12 LCA10 06
2
Entlüftung Kondensator
1/2" -- -- G1/2" -- Innengewin
SA-105
J 9 &12 LCA10 07 ventilation condenser de female
12 LCA10 04 Entleerung Kondensator Innengewin
N7 2 1/2" -- -- G1/2" Ø33,4 SA-105 J
&12 LCA10 05 emptying condenser de female
Austritt Kondensat Typ WN
N8 12 MAM60 08 1 1" 150 ASME B16.5 RF Ø33,4 SA-105
14 outlet condensate
Entleerung Kondensatschleife Innengewin
N9 1 1/2" -- -- G1/2" -- SA-105
emptying condensate loop de female
2 Austritt Sicherheitsventil Innengewin
N10 12 LCA10 03 1 1/2" -- -- G1/2" -- 316L
11 outlet safety valve de female
Anlagenschild
FS 1 -- -- -- -- 105 x 105 -- -- K
K 17 name plate of the unit
2
18 Transportangaben / Transport information 2
TOP VIEW
N N 17
W O
345 Zulässige Stutzenbelastung F = 5000N
W O
10 8 Permissible forces and moments
2 1445 [1443] S 150 150 L
S
2 FR MR FR MR
ML ML
667 778
L
GROBSTÜCKLISTE / LIST OF PARTS
Benennung /
B FU FU
Pos. No.
Nennweite
Material 12
designation / size 1 FL FL
150
MAM65AA020 MU MU
Anlagenschild name
R
Da
18 1 -- SS
93.5
plate 15 13 cylinder sphere

17 4 Tragöse lifting lug NG1 - DIN 1.0038 n18 n18 16 FR FL FU MR ML MU
28086 Stutzen M
Erdungslasche 310 t=10mm t=10mm 12 nozzle kN kN kN kNm kNm kNm
16 1 -- SS
earthing lug
485
M 15 147 [145] N1;N2 1,35 1,15 1 0,3 0,6 0,465

1 Traggestell support -- 1.0038 N3;N4 1,35 1,15 1 0,3 0,6 0,465
Druckmessung 121
14 1 pressure measuring 1/2'' -- 2 7
Kondensomat steam
1357
970
13 1 1'' --
trap
12 2
Absperrschieber
1'' -- N10 373 C.L Condenser 6 N
Gate valve
780
Rückschlagklappe --
N 11 2 3''
Non-return valve
Sicherheitsventil Detail Erdungslasche /
10 1 rohrseitig safety 1/2'' -- detail earthing connection Detail Verbindung Traggestell /
2
valve tube side
(1:2) Detail connection support frame
93.5
Absperrklappe mit
MAM65AA010 (1:2)
390
9 3 Rasthebel butterfly 3'' -- P

valve manual 30 20
Maße in [...] sind Ist-Maße
150 90 t=10mm 2
P Entlüftungsleitung 90 150 t=10mm measures in [...] are actual size

8 1 Kondensatableiter 1/2'' SS
B 675 AEL-Auftrags.Nr.: 4020005
10
drain line blower n18 n18
60
n11
45
Entleerungsleitung 1696

7 2 Gebläse drain line 1/2'' SS
70
4
3
150
blower
Kondensatablaufleitu 70 2 07.05.2021 SMI ARI ARI as built Q
1 Grobstückliste / list of parts
6 1 ng condensate line 3'' CS 19.02.2021 SMI ARI ARI
Erstausgabe / first issue
0 11.11.2020 SMI ARI ARI
Abluftleitung 150 M16
Q 5 1 3'' CS 150 Zust.
Rev.
Datum
Date
erstellt
drawn
geprüft
checked
genehmigt
approved
Bemerkungen
Remarks
exhaust line
Bypassleitung
A A 345
http://www.ana-gmbh.com
4 1 bypass line 3'' CS e-mail: [email protected]

GLAND STEAM CONDENSER
Zum Heben der Anlage wird die Verwendung einer einstellbaren H- Traverse empfohlen. MODULE - LAYOUT
Saugleitung suction Herrfurthstrasse 9 * D-06217 Merseburg
3 1 3'' CS Die Anlage darf nur an den 4 Hebeösen am Gestell gehoben werden. Tel.: 03461/457-0 * Fax: 03461/457-200 TIMOR 2 - 12 MAM60AC010
line
Grauguss
Es dürfen nur handelsübliche und für das Gewicht der Anlage zulässige Anschlagemittel bestimmungsgemäß verwendet werden. Fertigungsauftrag-Nr.: Blattgröße:
Sheet Size:
Maßstab:
Scale:
Zeichnung-Nr. / Drawing-No.: Rev. R
Production order-No.: Zust.
R 2 2 Gebläse blower 3''
(GG20) F220-3512
A0 1 : 10 67-3266 2
For lifting the unit, the use of an adjustable H- cross beam ist recommended. (14 487/2020)
Oberflächenkondensa
The unit may be lifted only at the lifting eyes at the rack. Werkstoff / Material: Hierzu / To this: Kunde / Customer: Siemens Gas & Power GmbH & Co. KG
1 1 tor surface 1,37 m2 CS/SS
Only commercial and slinging means permisible for the weight of the unit may be intended used. condenser tube sheet& tubes: 316L condenser shell: CS 65-2433 Projekt / Project: TIMOR 2
condenser supp.rack: 1.0038 piping: CS Bestell-Nr. / Order-No.: 7001021687
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24
Telefax (03461) 457-200
Operation Manual
1. Beschreibung/Description
Lüfter/ Fan 2x100% with Siemens Motor
Produkt:
Wrasendampf/Gland steam 1x100% surface condenser + 10%
Kondensator/condenser
Leistungsreserve
2. Leistungsdaten Kondensator /Performance data condenser

Druck/ Massenstrom/
Betriebsdaten/ Temp.
pressure mass flow
operating conditions
bar (a) °C kg/h
Lastfall/Load case Design-Case
Wrasendampf/ Luft/air 79,2
0,99 237,2
Gland steam Dampf/Steam 61,2
Kühlwasser/ ein/in 16,28 40,8
33000
cooling water aus/out 16,28-0,087 41,8
Gasaustritt/ Luft/air 79,2
0,988 67,2
gas outlet Dampf/steam 19,1
Dampfkondensat /
Wasser/ water 0,988 67,2 42,1
Steam condensate
Thermische Auslegung/
Suction flow acc. customer specification 5-62430-BB2285A
thermal calculations
3. Design and principle of operation
Related P&ID Gland steam system 0-06420-BB2284A-02
The steam flows into the shell side of the gland steam condenser where it is channeled around the internal
tubes by means of various baffle plates whereby it largely condenses on the cold cooling water pipes. The
condensate is collected in a water loop and leaves the module. Any non-condensable fractions of the
steam will be sucked in by the operating radial fan and will exit the module. The radial fan is specifically
designed to extract any non-condensed inert gases from the gland steam condenser module.
The cooling water flows through the condenser in single-pass. Cooling water enters the tube side of the
gland steam condenser, flows through the internal tubes, and exits the condenser. To guarantee the good
working order of functionality of the gland steam condenser, the flow directions shall not be reversed or
changed. Various ports are provided on the condenser for draining and venting.
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Operation Manual
4. (Un-) Installation Advices

All safety information or instructions mentioned herein will apply to the assembly, installation or
dismantling of plant sections or components even though the same may not be explicitly mentioned.
As with any activity, the installation job site will be off limits to unauthorized personnel.
As installation work may have to be carried out from a raised position and as detached or heavy
components may have to be handled, such work must be performed with particular care.
Assembly or installation work must not be carried out under pipes or fittings that have not been properly
fastened. Generally, make sure any work is carried out from a safe position.
Pipes or fittings may only be moved or handled by means of a hoist or lifting gear such as a crane or
manipulator. Moreover, they must be positively supported for safe working.
Here, too, it is mandatory to wear protective clothing, specifically hard hats and work gloves.
Exclusively suitable, safe and approved tools in good working order only may be used for such work.
A second backup person must be present for high-risk work or work at a raised position.
Plant components or sections may only be installed, dismantled or removed while de-energized.
When bolting up two pipes or their flanged ends, be sure to safely fasten and fix the flanges in position to
avoid hazards through falling parts.
Work on electrical or electronic systems may only be carried out by purposefully trained and adequately
qualified personnel.
Hazards through electric energy must be excluded. For detailed information or reference refer to the
regulations issued by VDE (the German Association for Electrical, Electronic & Information Technologies)
or local utilities.
Work on electrical or other drives may only be performed after the respective drive has been deactivated,
and secured against restart.
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Operation Manual
5. Disclaimer
ANA Prozesstechnik GmbH will not accept responsibility for any damage resulting from the non-
observance of these commissioning instructions or any documents included therein or of any assembly,
operating, maintenance or servicing instructions issued for individual components respectively.
Moreover, ANA Prozesstechnik GmbH disclaims liability for any damage caused by other uses of the gland
steam condenser module than the designated use, or by structural changes to the module.
This equally applies to any damage that could have been avoided through regular monitoring of
components subject to wear or through timely and proper maintenance or servicing.
In addition, ANA Prozesstechnik GmbH disclaims liability for any damage caused by acts of God or Force
Majeure, or extraneous cause.
During the warranty period, any required repairs or changes to the system should be exclusively done by
our servicing staff, or by your operating personnel or by external contractors following our prior written
consent only.
6. Operation Instructions
Make sure all persons working on or in connection with this gland steam condenser module will have
thoroughly read and understood these assembly instructions. All such work may exclusively be performed
by duly qualified and trained personnel only.
6.1. Before Start-up

Before starting the gland steam condenser module up, some precautions or provisions must be made, as
described in the technical comments. All the activities mentioned below must have been successfully
finalized before this unit may be started up.
 Set the module up.

 Fixing the module.
 Hook up all pipes / transfer points.
 Connect all ground connections (two (2) nos. on the base frame).
 Inspect / retighten all screw connections.
 Connect all electrical equipment items (level switch, radial fan).
 Work off the checklist - see technical comments.
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Operation Manual
The starting-up procedure may only commence once the checklist will have been worked off and the
quality plan will have been signed off.
• Inspect all transfer points for proper connection and hook-up.

• All shut-off valves must be open.
• The radial fans must be started up in line with the operating and maintenance instructions.
• Motors are activated in line with the operating and maintenance instructions.
• The condensate water supply must be opened.
• After that only, the steam may be allowed to flow into the module.
• Preferably, the steam should be opened gradually to allow the material to gradually adapt to the
temperature (difference).
6.2. Operation
Check operating values such as the steam temperature at the measuring points provided for this purpose
during the whole time of operation.
To guarantee the ongoing monitoring of the operating values and to avoid risks of accident, the facility
Operator or Owner respectively shall the gland steam condenser module and its proximity are maintained
in a state of order and cleanliness at all times while the unit is in operation. Moreover, the facility Operator
or Owner must guarantee that all instruments or measuring points are easily readable and in good working
order. The same will apply to the good working order of all valves or fittings.
If there is excessive noise on the gland steam condenser module, establish the cause, and eliminate as and
if required. Should it not be possible to establish the cause or should the noise level be alarmingly high,
shut this unit down as described here.
6.3. Shutdown
Before shutting the gland steam condenser module off and thus discontinuing the steam supply, it must
be guaranteed that this operation will be coordinated and concerted with the remaining automation
concept and the existing fail-safe systems. It must also be guaranteed that this will not be followed by any
automated operations to maintain the steam supply.
To shut the gland steam condenser down, proceed as follows:
 discontinue the steam supply at the steam inlet piece,
 after a wait time of ten (10) minutes, shut off the radial fans, and
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Operation Manual
 discontinue the cooling water supply.

Whether or not the gland steam condenser module will have to be drained will depend on the ambient
conditions. Here, specifically the ambient temperature is critical. The equipment will have to be drained if
there is a risk of the fluids (viz. the condensate and cooling water) beginning to set, solidify or freeze.
Whenever the ambient temperature TU is below or equal to zero degrees Celsius, the pipes and gland
steam condenser module will have to be completely drained.
Draining of water: ambient temperature TU ≤ 0 °C
As a basic principle, the processes must be coordinated with the overriding overall system when the
gland steam condenser module is shut down.
7. Safety regulations
These safety regulations are valid in connection with installation and operation instructions as mentioned
before and are to be observed strictly.
Operating personnel Be aware that all inspection, installation, maintenance and operation works are
performed by qualified personnel.
Personnel with a lack in technical knowledge related to the delivered unit must
be trained and instructed. If required, this instruction can be ordered by the
manufacturer / supplier.
The customer is responsible to train and instruct the operating and
maintenance personnel for the delivered. The customer has to guarantee, that
the operating and maintenance personnel is able to understand the content of
this installation and operation manual.
Dangers by non- Personnel, environment and machinery may be harmed by mechanical,
observance of safety thermal and/or chemical hazards.
regulations Malfunction or breakdown of the gland steam condenser unit or the whole
plant may occur.
The operation of the gland steam condenser unit beyond the specified process
data limits is strictly forbidden.
Safety at work Additional to this manual, national regulations regarding health and safety
have to be followed.
All hot (> 50°C) and cold (< 10°C) parts may inflict thermal damages and have
to be protected or insulated.
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Inspection, All works on the unit have to be performed after shut-down and cool-down.
installation and Prior working on pressure loaded or vacuum loaded parts all remaining
maintenance pressure or vacuum must be eliminated / vented.
Only genuine or authorized parts are to be used for the maintenance.
All control devices and safety equipment must be reinstalled and put into
operation directly after finishing the maintenance.
8. List of Parts
1 pc Gland steam condenser

2 pcs Radial fan
1 pc Piping incl. valves and siphon
6/6
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24
MAM65AN120-M01
M
A A
MAM50AA510 MAM50AA520 WASTE STEAM
MAM65
FAN
MAM50 BR020
BR010
MAM65AN120 MAM65AA520
MAM65AA020
MAM50AA010
MAM50AA020
MAM65
BR005
MAM65AA005
MAM65 02
B B
C
S
MAM65AN110-M01
H M
WASTE STEAM
Even without a label, or with the label "AL: N" oder "ECCN: N", authorization may be required due to the final end-used
when being export out of the EU. Goods labeled with "ECCN" not equal to "N" are subject to US reexport authorization.
MAM50
MAM50
BR010
BR020
MAM65 FAN MAM65
BR010 BR030
MAM65AA010 MAM65AN110 MAM65AA510 3"

Goods labeled with "AL" not equal to "N" are subject to European or German export authorization
MAM50
BR630
C C
MAM65
BR620
MAM50
BR030
LKZ: N
MAA10
MAM50 03 MAM65
BR610
S
C
and destination for which the goods are to be used.
ECCN: N
MAM50
MAW40
BR030
BR620
MAM50
BR610
MAW70 01
MAM50 01
C
S
D S D
MAM50 02
C
MAM65
BR010
PS = bara
TS = °C
TIA S
C
AL: N
C MAW40CT910
S TISCZA
MAW40CT910 MAW70 MAW70
R&I diagram steam system
BR010 BR020
0-06420-BB2284A-00
MAW40
TE TE
BR020
MAW70AA110 X1-IK-200-PRS-PID-00008
MAW40CT010 MAW40CT012
LCA10 03
PI X1
C
S
MAM60CP510
E TE E
LCA10AA310
MAW40CT011
TI
PIA
LCA10 07
LCA10CT520
PS = bara
LCA10 02
MAW40CP010
C
S
C
TS = °C
Max. OPERATING DATA
C
S
LCA10 05
PICA S
C
S
MAW40
15.20 barg 41.8 °C kg/s
BR611
min. 10xDN
MAW40CP010 LCA10
PT
3" P&I diagram condensate system
BR001
MAW40CP010 0-06420-BB2284A-10
LCA10AA710 TS = 60.0 °C X1-IK-210-PRS-PID-10001
TI PS = 27.05 barg
MAW40AC010
LCA10 01
TIA PIA MAW40AA810
WASTE STEAM LCA10CT510
C
S
MAW10CT201 MAW10CP201 MAM60AC010
C
TISA PISA S CONDENSER LCA10
F F
3"
kann sich eine Genehmigungspflicht, unter anderem durch den Endverbleib und den Verwendungszweck der Güter, ergeben.

MAW10CT201 MAW10CP201 BR002
MAW40
S
BR810
0-06420-BB2284A-10
TE PT C
TS = 60.0 °C
MAW20 02
LCA10AA610 X1-IK-210-PRS-PID-10001
bzw. deutschen Ausfuhrgenehmigungspflicht. Die mit "ECCN" ungleich "N" gekennzeichneten Güter unterliegen
MAW10CT201 MAW10CP201 PS = 27.05 barg

der US-Reexportgenehmigungspflicht. Auch ohne Kennzeichen, bzw. bei Kennzeichen "AL: N" oder "ECCN: N"
C
S
Max. OPERATING DATA
Die mit "AL" ungleich "N" gekennzeichneten Güter unterliegen bei der Ausfuhr aus der EU der europäischen
MAW40
LCA10 06
Max. OPERATING DATA
LCA10 04
1.03 bara 480.0 °C kg/s
C
S
BR010
C
S
MAW10 01
15.28 barg 40.6 °C 9.17 kg/s
1"
C
S
TS = 499.0 °C MAM60AA010 MAM60AA030
PS = 7.00 barg MAM60AA020
Max. OPERATING DATA 2" S
MAM60 08
MAW40
BR610
10.25 bara 485.0 °C 0.13 kg/s C
C
S
MAM60
MAW10 MAW20AT010 MAW30 3" BR010
P&ID Auxiliary Steam
LKZ: N
BR010 BR010 MAM60 01 0-06420-BB2284A-10

MAW40 01 MAW40 03 TS = 90.0 °C
G X1-IK-200-PRS-PID-00011 G
X1-IK-210-PRSS-PID-10002 TS = 505.0 °C free flow PS = 0.50 barg
PS = 10.80 barg <2m <1m S S X10
MAW20AA010 MAW20AA110
C C Emergency overflow
mech. design
ECCN: N
MAW10AA110
H H
AL: N
H
external drain system
Max. OPERATING DATA
n
7.00 barg 40.0 °C kg/s
o
Air Supply
i
external
s
TS = 65.0 °C
i
PS = 11.00 barg
J J
v
Legend of Symbology:
e
local (in field)
r R Turbine Control System (TCS)
f f ü Local control system (black box)
LCE30
BR020
K K
Distributed control system (DCS)
wu
t
Symbology acc. to DIN; DIN EN ISO; DIN EN
n
express authorization are prohibited. Offenders will be held liable for payment
of damages. All rights created by patent grant or registration of a utility model
well as utilization of its contents and communication thereof to others without
Transmittal, reproduction, dissemination and/or editing of this document as
E
Battery limit Customer connection
no....
C
C
S
S
LCE30 02
S = Siemens S = Siemens
C
L L
S
C = Customer C = Customer
LCE30 01
C
S
or design patent are reserved.
Max. OPERATING DATA

15.28 barg 40.9 °C kg/s Pipes symbology:
LCE30 Steam-air
BR001
0-06420-BB2284A-10
X1-IK-200-PRS-PID-00011 TS = 60.0 °C Air
PS = 27.05 barg LCE30AA110
C LCE30AA010
LCE30AT010 Gland steam
M M
D15
X1-IK-200-PRS-PID-00009
0-06420-BB2284A-01
P&I diagram drain system
N N
CONSORTIUM DWG. NO. :

X1-IK-200-PRS-PID-00010
For Sulut X = "S"
P
For Timor X = "T" P
Code Word: SULUT / TIMOR

Schadenersatz. Alle Rechte für den Fall der Patenterteilung, Gebrauchsmuster-
Weitergabe sowie Vervielfältigung, Verbreitung und/oder Bearbeitung dieses
Project No.: BB002284 / BB002285

Dokumentes, Verwertung und Mitteilung seines Inhaltes sind verboten,
soweit nicht ausdrücklich gestattet. Zuwiderhandlungen verpflichten zu
G 2021-02-15 Koppeel Guretzka Guretzka see Rev.-Index
Timor Sulut Rev.

Rev.
Blatt
Sheet
Entstanden aus:
Koord.
Coordin.
Datum
Date
erstellt
Prepared
mit Änderung:
bearb.
Checked
geprüft
Approved
Änderungsbeschreibung
Description of Change
1720-000006000E
Turbine 1 Turbine 2 Turbine 1 Turbine 2
Original of: with Revision:
Datum Name Maßstab
1:1 Specification: Norm
oder Geschmacksmustereintrag vorbehalten.
Date Name Scale

erstellt Benennung
2020-01-24 Koppeel
Title
P&I diagram Gland steam system
KKS-PREFIX 11 12 11 12
Prepared
bearb.
2020-01-24 Guretzka
Checked
Q geprüft
Approved
2020-01-24 Guretzka R&I-Fließbild Sperrdampfsystem Q
KKS 11 MAA10 12 MAA10 11 MAA10 12 MAA10 SIEMENS energy CAE
Format Ident-Nr./Unterlagen-Nr. Rev. Spr. Blatt
Gas and Power Size Ident-Number/Document-Number Rev. Lg. Sheet
SIEMENS No. BB002285A BB002285B BB002284A BB002284B A0 0-06420-BB2284A-02 G de en 1/1
Protection class: Restricted © Siemens Energy, 2020

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24
4. Installation- and safety instructions

4. Montageanleitung / Sicherheitshinweise
Commission-N°:
7001021687
Factory-N°:
4020005 Project:
TIMOR 2
Drawing-N°:
BB2285B
Baujahr: Pos.-Nr.:
2021 Pos.-N°.:
--
Installation: Only designed lifting lugs and -plugs are used to lift and transport of apparatus
respectively the unit.
It is inadmissible to use fixed prunings to lift!
The specified empty weight on the name plate is to observe when lifting!
The apparatus/ unit only lift and transport in empty condition!
The apparatus/ unit is to couple at foundation/ steel construction immediately
after installation.
Foundations respectively steel construction must meet structurally the requirements
for the installation! For it the maximum weight of apparatus/ unit in filled condition is
to be taken from the drawing respectively this operating instruction.
At installation it is to be provided for enough expansion space for inspections and
maintenance.
Mounting/ Piping: At connecting of pipeline do not overshoot the allowed nozzle load given on drawing!
Indicated starting torques for flange connectings are to be kept!
The extended pipeline must have the same rated pressure stage like apparatus-/
unit nozzles self.
Use only seals, which resist operating conditions as well as the medium!
Operation: Before starting a tightness check must be carried out!

Do not overshoot respectively undershoot the allowed upper limit and lower
limit for working pressure and working temperature!
Opening of inspection orifices or dismantle of pipelines are carried out only
in depressurized conditions respectively unit standstill! In every case a release
have to be overtaken by an appropriate pass note by operator.
Apparatus/ unit may be operated only with media for which it is designed.
Only authorized persons should serve mounted fittings.
Maintenance/ Inspection: The essential inspection intervals have to be kept. These are prescribed for
operator by control equipment!
5. Lagerungshinweise
5. Storage instructions

Commission-N°:
7001021687
Factory-N°:
4020005 Project:
TIMOR 2
Drawing-N°:
BB2285B
Baujahr: Pos.-Nr.:
2021 Pos.-N°.:
--
Lagerung: Die Lagerung muss in einem unbeheizten und trockenen Lagerraum erfolgen!
Es ist darauf zu achten, dass die Anschlussstutzen bis zur Montage der
Anschlussrohrleitungen verschlossen bleiben, um ein eventuelles Eindringen von
Feuchtigkeit auszuschließen.
Der Transport zum und vom Lagerplatz ist mit den dafür geeigneten Transportmitteln
vorzunehmen.
Das Anheben der Anlage darf nur über die dafür vorgesehenen Tragösen erfolgen.
Storage: The storage have to occur in a unfired and dry depot.

Connecting nozzles have to be closed until installation of the connecting pipelines,
because it have to be excluded a entry of dampness.
The transport to and from storage is made with suitable means of transport.
The elevate of the unit may occur with allowed hitches.
Lagerung
im
Gebäude
storage
in
a hall
6. Leckdampf-Kondensator
6. Gland Steam Condenser

Commission-N°:
7001021687
Factory-N°:
4020005 Project:
TIMOR 2
Drawing-N°:
BB2285B
Baujahr: Pos.-Nr.:
Komponente: Leckdampf-Kondensator 12MAM60AC010

component: Gland Steam Condenser
Zeichnung 65-2433X - Rev. 2

1.
Drawing 65-2433X - Rev. 2
Betriebs- und Wartungsanleitung
2.
Operating and Maintenance Manual
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
Vorschriften:
Abnahme:
Inspection by
A DESIGNER: ANA Prozesstechnik GmbH A

MANUFACTURER: AEL Apparatebau GmbH Mantelseite Rohrseite
min. / max. bar Ü
1445 [1444] 2 max. zul. Druck
-1 / 0,5 0 / 27,05 bar g
N3 max. zul. Temperatur min. / max.
Allowable working temperature TS 5 / 325 5 / 60 °C
N3 N4 N4 bar Ü
322 750 373 [372] 2 Verfahrensdruck
Operating pressure -0,01 ... 0 15,2 ... 15,3 bar g
N6 Verfahrenstemperatur 67,2 ... 237,2 40,8 ... 41,8 °C
2 Operating temperature
N6 N6 mit Wasser 20°C - Lage horizontal
175 [174] 225 Prüfüberdruck 3,0 36,5
116 [117]
116 [117]
testing pressure with water 20°C - horicontal position PT bar Ü
bar g
121 mit Luft (Leckagetest)
N/A N/A
2
2
with air (leakage test)
N8
200
Inhalt gesamt
volume total
15,0 7,6 l
Wärmeaustauschfläche 1,37 m
2
n168.3
B Heat exchanging area
B
410 [412]
Fabrik-Nr.
Factory-No. 301 543 ; 3120003
N1 N2 FS Baujahr
Year of construction 2021
Medium Luft, Dampf Kühlwasser
2 medium air, steam cooling water
176
gasförmig flüssig
200
Aggregatzustand
210
116 [118]
N7 A A B B Dichte
density
0,53 ... 980 992 ... 993 kg/m
3
2 toxisch / brennbar / explosiv NEIN / NO NEIN / NO

175 [174] 225 Fluidgruppe
Fluid group
-- --
322 T1 T2 N7 N5 Schweissnahtfaktor
N5 N7 Korrosionszuschlag
520 555
C Längsnähte C
Röntgen / U.S.-Pruefung Long. welds
der Schweissnähte Rundnähte
Circ. welds
X-ray / ultrasonic testing
of welds T-Stoesse
T-joint
Andere Prüfungen siehe Schweiß- und
Other tests Prüfplan
in acc. to welding and test plan
Schweissverfahren 156891
Welding process
Vorwärmung ja/nein
Pre-Heating yes/no
Wärmebehandlung ja/nein
1445 Heat treatment yes/no
Insulation warm/cold -- mm
D Auskleidung
D
Lining -- mm
Oberflächenausführung aussen gemäß ANA Anstrichkonzept
Abmaße und Toleranzen nach DIN 28008, Genauigkeitsgrad AR Surface finish outside
measurements and tolerances acc. DIN 28008, grade AR
acc. to ANA painting concept
N1 N2 Vor dem Versand ist der Wärmetauscher von inneren und äußeren
Gewicht
Verunreinigungen zu säubern und zu entleeren. Weight 100 kg
prior to shipping the vessel must be free from impurities and Gewicht mit Wasserfüllung
Weight full with water 122,6 kg
residues and all internal parts must be drained Betriebsgewicht
operating weight 115 kg
Bemerkungen Allgemeintoleranzen: für Schweißkonstruktionen - EN ISO 13920 Klasse-B+F ; Lastspiele ≤ 500 ( gem. ASME Sec.VIII )
Remarks
322
E general allowances: for welding construction - EN ISO 13920 class-B+F; load application ≤ 500 ( acc. to ASME Sec.VIII ) E
FS
N8
A-A ( 1 : 5 ) B-B ( 1 : 5 ) N6
N4
N2
120
120
R9
F 60 n18.5 45 40 .25 F
SUTZENTABELLE / table of nozzle N3

Bez. Anz. Benennung DN Standard Dichtfläche Rohrabmessung Bemerkung
designation Class
des. no. NPS standard gasket surf. dimens. of tubes remarks
Kühlwassereintritt Firmenschild / name plate N6
N1 1 3" 300 ASME B16.5 RF Ø88,9x5,49 3" STD Maße in [...] sind Ist-Maße
cooling water inlet N7 measures in [...] are actual size
Kühlwasseraustritt MADE IN GERMANY
N2 1 3" 300 ASME B16.5 RF Ø88,9x5,49 3" STD Hersteller/ Manufacturer
cooling water outlet ANA PROZESSTECHNIK GmbH
G
N3 1
Brüdeneintritt
vapor inlet 3" 150 ASME B16.5 RF Ø88,9x5,49 3" STD ANA-Kommission
ANA-Commission
Herrfurthstraße 9
06217 Merseburg
F220-3512-002 AEL APPARATEBAU GmbH

T2 AEL-Nr.: 3120003 G
Brüdenaustritt Benennung
gland steam condenser 5

N4 1 3" 150 ASME B16.5 RF Ø88,9x5,49 3" STD Designation
vapor outlet geltende Normen 4

applicable norm
3
Kondensataustritt AEL-Fabrik-Nr.
301 543 ; 3120003 Baujahr
2021 Lochstellung von asbuilt [...]
N5 1 3" 150 ASME B16.5 RF Ø88,9x5,49 3" STD AEL-Serial No. Year built 2 16.20.2021 TTE SMI
condensate outlet Mantelseite / shell side Rohrseite / tube side Flanschen, wenn nicht

1 11.12.2020 Gö Ga Ga Schweißtechnik
m. Verschlussschraube min./max. allowed pressure
[PS] 5 / 325 bar g -0,01 ... 0,0 bar g anders angegeben 0 09.11.2020 TTE SMI Erstausgabe / first issue
N6 2 Entlüftung ventilation 1/2" -- AELS 2851 -- -- min./max. zulässige Temperatur [TS] 5 / 60 °C 15,2 ... 15,3 °C Position of flange
with screw min./max. allowed temperature T1 Zust. Datum erstellt geprüft genehmigt Bemerkungen
Prüfdruck
Test pressure
[PT] 3,0 bar g 36,5 bar g
unless otherwise Rev. Date drawn checked approved Remarks
Entleerung emptying -- -- -- m. Verschlussschraube Inhalt [V] stipulated

N7 2 1/2" AELS 2851 Volume 15,0 l 7,6 l
with screw
Messstelle
Leergewicht
Empty weight
Betriebsgewicht
Operating weight
N1 FS http://www.ana-gmbh.com
e-mail: [email protected]
N8 1 pressure measurement 1/2"
-- AELS 2851 -- -- -- 100 kg 115 kg
Herrfurthstrasse 9 * D-06217 Merseburg
gland steam condenser
Prüfdatum
Test date
Monat/Jahr
Month/Year
N5 Tel.: 03461/457-0 * Fax: 03461/457-200
Festlager -- -- -- -- -- --
H T1 1 Bei Ersatzteilbestellung Fabrik-Nr.und Baujahr angeben. Fertigungsauftrag-Nr.: Blattgröße: Maßstab: Zeichnung-Nr. / Drawing-No.:
fixed saddle When ordering spares, please state serial no. and year built.
N7 Production order-No.: Sheet Size: Scale:
Rev.
Zust.
H
T2 1
Loslager
-- -- -- -- -- --
F220-3512
(14 488/2020)
A1 1:5 65-2433X 2
sliding saddle
Werkstoff / Material: Hierzu / To this: Kunde / Customer: Siemens Gas & Power GmbH & Co. KG
Firmenschild shell side: Gr.B bolts/nuts/gasket: --
FS 1 -- -- -- -- -- 120x120x75 65-2433 Projekt / Project: Timor 2
name plate tube side: TP316L tube sheet: TP316L Bestell-Nr. / Order-No.: 7001021687
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
Deckblatt / Cover sheet
- Montageanleitung / installation manual

- Inbetriebsetzungsanleitung / start-up manual
- Betriebs- und Wartungsanleitung /
operation and maintenance manual
Customer: ANA Prozesstechnik GmbH

(Siemens Global Energy GmbH & Co. KG)
Standort / location: Deutschland

Bestell-Nr. / Order-no.: B221-18215-3512
Projekt-Nr. / Project-no: -
Projekt Kennwort / Project code word: TIMOR 2
Manufacturer: AEL Apparatebau GmbH Leisnig

Döbelner Straße 9
04703 Leisnig
Benennung / denomination: Gland Steam Condenser
Projekt / project: TIMOR 2
AEL Kommissions-Nr. / job no.: 3120003
AEL Zeichnungs-Nr. / drawing no.: 65-2433X
Ident-Nr. / ident no.: 1203.100596
Baujahr / year of manufacture: 2021
Allgemeine Dokumentation für

Rohrbündelwärmeübertrager
00 Erstausgabe / First issue 03.06.21 Böttger Stollberg General documentation for

Rev. Beschreibung Datum erstellt geprüft Shell- and tube heat Exchangers
Description date designed check
Kunde / customer Format
size
A4
ANA Prozesstechnik Dok.-Nr. / Blatt / sheet Rev.
GmbH doc no.:
1 von 24 / 00
1 of 24
Content
1 Preliminary Remarks ........................................................................ 3

1.1 General Information ........................................................................................................................ 3
1.2 Safety Information............................................................................................................................ 4
1.2.1 General Information ............................................................................................................... 4
1.2.2 Selection and Qualification of the Personnel.......................................................................... 5
1.2.3 Warning Notices and Safety Symbols .................................................................................... 6
1.3 Exclusion of Liability ....................................................................................................................... 7
2 Installation Manual ........................................................................... 8
2.1 Scope of Installation ......................................................................................................................... 8
2.2 Prerequisites...................................................................................................................................... 8
2.3 Necessary Tools and Aids ................................................................................................................ 8
2.4 Performance of Installation ............................................................................................................. 9
2.4.1 Transport and Storage ............................................................................................................. 9
2.4.2 General Installation Information........................................................................................... 10
2.4.3 Installation Manual ............................................................................................................... 10
2.5 Recording – Installation – Inspection Sequence Plan ................................................................. 12
3 Operational and Thermal Design Data ......................................... 12
4 Start-up Manual............................................................................... 14
4.1 Media and Material ........................................................................................................................ 14
4.2 Start-up............................................................................................................................................ 14
4.3 Operation......................................................................................................................................... 16
4.4 Troubleshooting .............................................................................................................................. 17
5 Repair Work and Maintenance Instructions ................................ 18
5.1 Shutdown ......................................................................................................................................... 18
5.2 Disassembly ..................................................................................................................................... 18
5.3 Cleaning ........................................................................................................................................... 19
5.4 Maintenance .................................................................................................................................... 20
5.5 Options of Repair ........................................................................................................................... 21
5.6 Reassembly / Pressure Test............................................................................................................ 21
5.7 Restart ............................................................................................................................................. 22
5.8 Operation......................................................................................................................................... 22
5.9 Spare and Wear Parts .................................................................................................................... 22
5.10 Service AEL .................................................................................................................................... 23
6 Annexes ............................................................................................. 24
6.1 Annexe 1: Forms for the Recording Repeated Pressure Test..................................................... 24
1 Preliminary Remarks
1.1 General Information
This manual shall necessarily be submitted for the attention of the operating personnel before
start-up, maintenance and repair.
a) The following instructions are based on the theoretical and practical experiences of the
manufacturer.
b) The instructions alone cannot, of course, contain a complete description of the operation of
the tube bundle heat exchanger and of all possible safety measures. In the case of doubts
relating to the operation of the tube bundle heat exchanger and safety measures related to it
the manufacturer is at the disposal of the plant owner/plant operator until the end of the
warranty period.
c) The manufacturer recommends to the owner/operator of the plant to train the operating
personnel according to these instructions and to ensure that these personnel have understood
the information and safety measures obtained and that it will respect them.
d) This plant shall be operated and maintained only by well-trained and responsibly qualified
personnel.
zu Schadenersatz.
e) These instructions shall not affect the responsibility of the plant owner/operator for the
operation and the safety of the tube bundle heat exchanger/s.
f) In any case the owner/operator of the plant has to comply with the relevant and legally
applicable public regulations, recommendations and guidelines and/or with those of
professional associations (environmental protection, accident prevention and/or safety
measures for the worker etc.).This also applies if individual provisions, standards and
guidelines are not mentioned herein. Order-related specifications (if any) shall also be
observed.
g) During the warranty period, repair or modification work on the tube bundle heat exchanger
shall be carried out exclusively by the service personnel of the manufacturer or, only after a
prior written approval by the manufacturer, by the personnel of the plant owner/operator or
by third parties.
h) The operator shall by means of appropriate safety installations ensure that an overstepping
both of the operating conditions indicated on the factory nameplate/the drawing and of the
permissible load changes of the tube bundle heat exchanger will be precluded.
i) In the case of any changes to the operating data or modifications of the tube bundle heat
exchanger without written approval of the manufacturer all responsibility of the manufacturer
related to the tube bundle heat exchanger shall cease.
j) The manufacturer does not assume any warranty obligation and/or responsibility for damages
resulting from the failure to observe this instruction.
k) The manufacturer cannot be held liable for indirect or consequential damages.
l) The manufacturer does not assume any responsibility for the deterioration of any parts or of
any equipment component caused by corrosion, erosion, improper operation or other reasons,
no matter when such defects occur after the leaving of the manufacturer’s factory workshop,
with the exception of the warranty claims stated in the contract.

m) In the case of warranty claims the manufacturer reserves the right to request the fully
completed installation inspection sequence plan (see installation manual), the completed
record of repeated pressure tests (if already carried out during this period) as well as the
complete documented evidence that the following indications which form the basis of the
construction have been respected during the operating period:
- parameter of the data sheet, see point 3 (e.g. pressures, temperatures, throughputs,
media),
- temperature changing speeds (max. 5 K per minute),
- pressure changes speeds (The pressure increase permissible per time unit when there is
pressure stress shall not exceed 0.5 bar per minute).
n) In the case of a discrepancy within this document the manufacturer shall be contacted
immediately. The German version of this document is to be considered as the legally binding
version; it is available at the manufacturer and can be delivered at any time.
o) If in the document there is reference made to “drawings”, always the apparatus specific
drawings listed in point 6.3 shall apply. Other drawings are stated separately.
1.2 Safety Information

zu Schadenersatz.
1.2.1 General Information
a) The tube bundle heat exchanger shall not be used for other purposes than those it is intended
for. In the case of use not compliant with the intended use the liability of the manufacturer
expires.
b) When working with media which are hazardous/harmful to health, e. g. hot media, irritant
media, inert gases at transportation fillings, the relevant provisions and sets of rules shall be
complied with. The hazard area shall be indicated.
c) Leakages, leaked or spilled fluids shall be removed immediately and shall be disposed of
properly. The hazard area shall be indicated.
d) The operating personnel shall regularly be advised of special hazards and there shall be
trainings on how to deal with these hazards.
e) It is recommended to wear helmets and non-slip working protective shoes.
f) Generally, the work on the tube bundle heat exchanger is only allowed in the depressurized
state and at temperatures excluding any damage to health. As the case may be the tube
bundle heat exchanger may be drained. The tube lines leading to the tube bundle heat
exchanger shall be blocked.
g) During the whole operating time of the tube bundle heat exchanger order and cleanliness
shall be observed. This applies especially to controls and instruments which need to be fully
functional and good to read at any time. When loose parts or tools are left this may cause
severe dangers - so this shall absolutely be avoided.

h) Plant components whose surface temperature may rise up to above 60 °C during operation
shall be marked in a clearly readable manner with the sign “Hot Surfaces” or shall be
isolated in the appropriate way. The warning notices are always to be kept clean and
completely and well readable.
i) Should there be inadmissible high vibrations during operation the reason therefore shall be
identified immediately and as the case may be may be eliminated in consultation with the
AEL Apparatebau GmbH Leisnig. If these vibrations cause a clearly identifiable danger to
persons, the apparatus and the environment, the tube bundle heat exchanger must be turned
off in a controlled way as described in this operation manual.
1.2.2 Selection and Qualification of the Personnel
The personnel for the operation, maintenance, transport and storage needs to have the
appropriate qualification which is relevant for the works to be carried out. The scope of
responsibilities, competences and supervision of the personnel must be clearly regulated by the
operator. If the personnel do not have the required knowledge it shall be trained and instructed
accordingly before the first start-up. If necessary and by order of the operator of the tube bundle
heat exchanger, this may be carried out by the manufacturer/supplier. Furthermore, the operator
shall ensure that the operation and installation manuals are read completely and that their
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contents are understood.
Furthermore, all persons who carry out works in relation to the tube bundle heat exchanger shall
meet the legal provisions such as the required minimum age, and they must not be under the
influence of mind-altering substances such as medicines, alcohol or drugs.

1.2.3 Warning Notices and Safety Symbols
The warning notices and safety symbols attached by the operator of the tube bundle heat ex-
changer shall be observed.
observance, cause dangers to persons, shall be marked with a general danger symbol
Electrical voltage warnings shall be marked with the

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or shall be labelled with the word
CAUTION!
observance, cause dangers to the machine or malfunctions additionally contain the word
CAUTION.
Notes directly attached on the machine, e. g.

- rotation direction arrow
- markings for fluid connections
- warnings of hot surfaces
- warning of hand injuries
- lift only with crossbeam / lifting point
shall absolutely be observed and kept in a completely readable state.
The existing national and international regulations on accident prevention as well as possible
internal company regulations on work, operating and safety shall apply in parallel with the safety
notices stated in this installation manual

Failure to comply with the safety notices may cause dangers to persons, the environment and the
machine. Furthermore, failure to comply with the safety notices results in the loss of any claim
for damages against the manufacturer.

In detail, the non-compliance may result for instance in the following dangers:
- danger to persons because of electrical, mechanical and chemical influences
- failure of important functions of the machine/plant
- failure of the prescribed methods of maintenance and repair
1.3 Exclusion of Liability
The AEL Apparatebau GmbH Leisnig cannot assume any responsibilities for damages resulting
from the failure to observe these installation, operation and maintenance manuals and the docu-
ments included therein.
Also excluded is any liability of the AEL Apparatebau GmbH Leisnig for damages caused by a
use other than the intended use and by unauthorised structural modifications at the tube bundle
heat exchanger. This also applies to damages which could have been prevented by a regular
monitoring of such parts subject to wear and by timely and proper repair works.
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In addition, AEL Apparatebau GmbH Leisnig assumes no liability for any damage arising from
events of force majeure or from external interference.
During the guarantee period repair and modification works on the machine that may become
necessary shall be carried out exclusively by our service personnel or, after our prior written
approval, by the operating personnel or third parties.
Original spare parts and accessories authorized by the manufacturer serve to enhance safety. The
use of other parts may annul the liability for the consequences resulting therefrom.

2 Installation Manual
2.1 Scope of Installation
 Installation of the tube bundle heat exchanger/s

 Connecting the tube lines
 Installation of the measuring instruments, if any
 Installation of the isolation, if any
 Grounding
 Recording (see point 2.5)
2.2 Prerequisites
 Completeness of the delivery according to the shipping list of items

 Prepared, vertical, flat and sufficiently dimensioned base / framework with anchor screws,
respectively steel construction with bolted connections
 Qualified installation personnel
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 Accessibility to the place of installation for transport vehicles and hoisting gears
 Sufficiently fixed ground for transport vehicles and hoisting gears
2.3 Necessary Tools and Aids
 Hoisting gears (e. g. crane) and sling gears for installation

(weight indications see drawing No. on cover sheet)
 Levelling device for the alignment of the tube bundle heat exchanger/s
 Screw tightening device with torque adjustment and indication

 Diverse tools (screw wrench, screw driver etc.)
 Platform of framework for the installation of the tube pipes and the controls
 Detergent and cleaning agents

2.4 Performance of Installation
2.4.1 Transport and Storage
a) In the context of a construction and first pressure inspection at the manufacturer's works with
the required inspection pressures (see drawing No. on cover sheet) the tube bundle heat
exchanger has been checked for flawless leak tightness.
b) Attention must be paid to ensure that damage caused by external influences is excluded
during transport, storage and installation. The tube bundle heat exchangers shall be stored
correctly, at a dry place, under a roof or carefully covered. All openings shall be closed.
c) For the transport on the building site the ground should be stabilized by means of crushed
stone, gravel bedding and concrete slabs and accessible for vehicles and hoisting gears.
d) The slinging for transport shall be carried out at the attachments points provided for this
purpose. When using carrying devices such as belt straps the corresponding safety
regulations and guidelines of the country in which the apparatus is installed shall be
observed.
e) Tube bundle heat exchangers of a horizontal installation type shall be placed on the saddle
bearings, vertical/standing tube bundle heat exchangers on the legs, the wooden slide or the
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like. Attention shall be paid to ensure that the diverse attachment parts (nozzles, steel
construction clips and the like) are not used for hoisting, that they do no touch the ground or
are not damaged in any other way.
f) To protect the coating bare steel ropes or chains are not permissible for the transport. When
using suspension ropes it shall be ensured that these ropes are secured against slipping
g) If the tube bundle heat exchangers are filled with nitrogen (e. g. p=0.5 bar (g)), the nitrogen
shall be discharged completely at the fixed shut-off valve prior to the installation and in
compliance with the relevant safety requirements (suffocation hazard).
h) The cover lids attached when leaving the manufacturer’s works shall be removed only
shortly before installation and only from the depressurized apparatus.
i) If the scope of delivery includes spare seals, special care shall be taken during their transport
and storage in order to prevent damages. Depending on their size, the seals are fixed in
boxes, cases or on cardboard papers and shall always be transported in a horizontal state
(manufacturer's instruction) in order to prevent that the coatings (e .g. graphite in the case of
grooved gaskets) peel off from the base material.

2.4.2 General Installation Information
a) Installation of the tube bundle heat exchanger/s according to the installation plan of the plant
operator.
b) Tube lines and shut-off devices shall be mounted without any tension. It shall be ensured
that, also during the operation, no inadmissible tensions, forces, torques and vibrations are
transferred to the tube bundle heat exchanger. All tube line connections must be mounted.
c) For the tube line connection pay attention to the inlet and outlet sides. The tube line routing
is laid according to the tube line plan of the plant operator.
d) The tube bundle heat exchangers shall be safely anchored in the base and at the framework
respectively.
e) In order to compensate thermal expansions of horizontal tube bundle heat exchangers the
slide bearing shall be anchored in way that allows for the necessary sliding movement
without restrictions.
f) For the integration of the anchor screws of standing tube bundle heat exchangers into a base
the base ring template included in the delivery shall be used if agreed.
g) In the case of tube bundle heat exchangers of the construction type with screwed or welded
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floating head and U tube bundles, there shall be - on the fixed head tube sheet side - a free
space of the length of at least the length of the tube bundle, if the tube bundle shall be pulled
at the place of installation. Moreover, enough space shall be provided for the removal of the
hood/chambers. Where applicable, the pivoting range of the installation and disassembly
equipment (pivot arms, hinges) shall be kept free.
h) In the case of tube bundle heat exchangers with compensator protection this protections shall
be removed in order to ensure the mobility (expansion compensation) of the heat exchanger
in the operating mode.

i) If there are any adsorbents such as gel pouches, transport and nozzle locks, all of them shall
be removed.
j) If a tube bundle heat exchanger is not put into operation for a longer period of time (approx.
half a year), a renewal of the seals is recommended especially for the soft-material gaskets.
k) Opened flange connections shall be equipped with new seals before the reinstallation -
after the cleaning of the sealing surfaces and the possible elimination of damages. The
installation of seals must be carried out with the utmost care. Defect seals shall not be
installed. The thread of screws and nuts shall be treated with an appropriate lubricant.
l) All flange connections shall be equipped with the number of screws indicated on the
drawing, to be tightened cross wise and clockwise progressing over the whole
circumference.
m) In order to prevent electrostatic charging the tube bundle heat exchangers shall be grounded
(grounding points see drawing No. on cover sheet).
2.4.3 Installation Manual

a) All tube bundle heat exchangers and accessory parts have been labelled at the
manufacturer’s premises. The parts included in the delivery shall be checked for
completeness with the shipping list of items and the list of loose parts.
b) The construction components and connecting elements necessary for the installation of the
tube bundle heat exchangers shall be taken out and laid out according to the installation
sequence.
c) Horizontal (lying) tube bundle heat exchangers:
Adjustment and screwing of the lower saddle bearings on the base
The tube bundle heat exchanger stands on at least two saddle bearings. The allocation of
fixed bearing and slide bearing is indicated on the drawing.
In order to compensate the thermal expansions of horizontal tube bundle heat exchangers
the other slide bearing shall be anchored in way that allows for the necessary sliding
movement without restrictions. It shall be observed that a sliding plate, which may exist,
is installed between the base and saddle bearing.
Vertical tube bundle heat exchangers:
Vertical tube bundle heat exchangers may be designed upright (e. g. by means skirt
support) or suspended (e .g. by means of support claw, support ring). In order to
compensate the thermal expansions the fastening must be carried out in an appropriate
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way (e. g. with counter nut), to allow for the movement in horizontal direction.
Furthermore, as a consequence of thermal expansion it must be ensured that there is
enough free moving space in vertical direction.
d) Screwings and flange connections shall be tightened cross wise and clockwise, progressing
over the whole circumference. The thread of all screws and nuts shall be treated with an
appropriate lubricant. Before integrating the seals the sealing surfaces shall be checked for
cleanliness and evenness. Defect seals shall not be installed.
e) The grounding of the tube bundle heat exchangers shall be carried out at the marked parts
(see drawing No. on cover sheet).

f) If the mounting of installation and disassembly equipment (pivot arms, hinges) for the
chambers, covers etc. has not been agreed when ordering the tube bundle heat exchangers, a
suitable accessibility for mobile hoisting gears must be ensured.
g) After completion of the installation works the inspection sequence plan (see point 2.5) shall
be completed and checked for completeness of the inspection results and for signatures. In
the table “Accuracy of Inspection Results” the check must be confirmed by signature.

2.5 Recording – Installation – Inspection Sequence Plan
System / Component: Applicable Installation Instruction No.:
Installation contractor: Annexes:
Scope of inspection Inspected by Inspection result Date / Signature

EC Cl II A
V
Completeness of the delivery, h i i
see packing list
Distance nitrogen filling, gel h

pouch (as far as existent)
Installation and fastening of the h

tube bundle heat exchanger on
the base plate / framework,
Inspection of the adjustment
Inspection of the safety

installations against excessive h
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pressure
Inspection - check of the

installation of tube lines for h
correct connection to the inlet
and outlet device
Inspection of the tightening

torques of the flange h i i
connections
Grounding of the heat

exchanger/s h i i
Leak tightness test of the tube

bundle heat exchanger in the h i i h
context of the complete plant
h – stopping point(participation in the inspection is absolutely required)
i – information point(information shall be provided prior to the inspection)
For the accuracy of the inspection results

Installation contractor Client Independent inspector(II) Advisor / Supervisor
(EC) (Cl) (AV)
Name
Date
Signa-ture
3 Operational and Thermal Design Data

Pressure chamber Shell Tube
side side
maximum permissible pressure PS -1/0,5 0/27,05

(bar)
min. / max. permissible temperature TS 5/325 5/60
(°C)
volume V 15 7,6
(l)
medium steam, air cooling
water
fluid group according to DGRL 2 2
physical state at operating pressure gaseous liquid
max. permissible number of stress cycles ≤ 500

test pressure PT 3,0 36,5
(bar)
year of manufacture 2021
average wall temperature °C (only for fixed
bundles)
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Remarks:
Unless otherwise stated, the operation and design data (see drawings) are determined by the
process owner.

4 Start-up Manual
4.1 Media and Material
a) The used materials are carefully selected and determined by the customer/operator. All
provisions of the process owner on the media composition shall be met.
b) The compatibility (appropriateness) of the fluids with the pressure device applications and
with the seals shall be proved by the operator in the context of the inspection prior to the
start-up.
c) Negative effects on the corrosion behaviour and the material resistance resulting from the
effects of additives (e. g. inhibitors) and/or whose usage was has not been approved by the
process owner shall not be at the expense of manufacturer of the tube bundle heat exchanger.
4.2 Start-up
a) The operator shall be responsible for the necessary safety measures. The permissible
operating parameters of the tube bundle heat exchanger/s indicated on the factory nameplate
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and the drawing must be met and must not be exceeded.

b) Prior to the start-up the transport equipment must absolutely be removed, the fastenings of
the fixed callipers and sliding callipers shall be checked.
c) In the case of flange connections with seals, all bolts of the flange connections shall be
retightened prior to the start-up. The bolts are to be tightened evenly with the tightening
torques indicated on the drawing. The retightening of the bolts shall be carried out cross wise
and clockwise progressing over the whole circumference.
d) Pressure chambers with fluid media shall be vented completely. Especially during and after
the filling repeated venting shall be carried out. The venting state shall be regularly checked.
e) The minimum and maximum values (e. g. pressures, temperatures) stated in the data sheet
(see point 3) shall not be exceeded.
f) In the case of tube bundle heat exchangers with stuffing box, the leak-tightness of the
stuffing box shall be checked continuously until the operating parameters are achieved.
g) Tube bundle heat exchanger with fixed bundles and respectively with stuffing box and
single-flow tube bundle heat exchangers with floating head:
- To avoid inadmissible wall temperature differences, the shell side shall always be started
first and the tube side shall be connected afterwards. When shutting down, the shell side
is to be shut down after the tube side.
h) Tube bundle heat exchangers with floating head (except for single-flow) and U tube bundles:
- At first load with a colder medium, irrespective if in the shell or the tube side.

i) During the start-up of the tube bundle heat exchangers sudden pressure and temperature
changes shall be avoided. The pressure increase permissible per minute when there is
pressure stress shall not exceed 0.5 bar per minute, in this context point 4.2 j) must absolutely
be considered.
j) In order to prevent temperature shocks, cold rooms shall not be suddenly loaded with hot
media and hot rooms shall not be suddenly loaded with cold media. By carefully dosing the
media a slow heating and cooling of both types of media rooms shall be envisaged. 5 K per
minute shall be considered as the maximum guiding value for the heating-up rate. A gradual
heating-up with longer dwell times is recommended.
The winter starting conditions for tube bundle heat exchangers for Russia see annexe 6.1.
k) If there are leakages at the flange connections the tube bundle heat exchanger must be shut
the bolts shall be carried out cross wise and clockwise progressing over the whole circumfer-
ence. In no case must be retightened only the bolts in the direct proximity of the leakages. A
pressurization is admissible only when all screws are integrated and tightened. If leak-
tightness is not achieved, the sealing shall be replaced. The shutdown shall be effected ac-
cording to point 5.1.
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l) The first start-up of coolers made of copper-nickel-zinc alloys shall be effected with clean
water over a period of at least three weeks. The pH value shall be between 7.5 and 8.5.
The flow velocity of the cooling water within the tubes shall be within the range of 1.5 m/s
up to 2.5 m/s. A continuous operation with a flow velocity as constant as possible shall be
ensured.
Stoppages shall be avoided, just as the drying-out of the inner tube surfaces.
The development of biological activities within the cooling water – especially within the
tubes – must be prevented, in the case that a formation of biofilms on the tube surface is
caused by these activities. Generally, the compliance with the above mentioned flow veloci-
ties prevents the formation of biofilms.
In individual cases the use of biocides may be necessary.
Hydrogen sulphide and sulphides shall be kept away from the cooling water.

4.3 Operation
a) The tube bundle heat exchanger is designed for the operating conditions submitted to the
manufacturer. In the case of deviations the manufacturer shall be consulted.
b) The venting state in pressure chambers with fluid media shall be checked regularly. As the
case may be repeated venting shall be carried out.
c) The product feeding shall be regulated in such a manner that a sudden temperature and
pressure change can be prevented. 5 K per minute shall be considered as the maximum
guiding value for the rate of temperature change. The heating-up of the tube bundle heat-
exchanger shall be effected in a manner that no inadmissible thermal stress may occur.
d) The pressure increase permissible per time unit when there is pressure stress shall not exceed
0.5 bar per minute, in compliance with point 4.3 c).
e) The minimum and maximum values (e. g. pressures, temperatures, throughputs) indicated in
the data sheet (see point 3) shall not be exceeded.
During the operation of heat exchangers with fixed tube bundle, it must be ensured that no
inadmissible temperature differences may occur between the stated average shell wall
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temperatures and the stated average tube wall temperatures that were at the basis of the
thermal engineering calculations of the apparatus.
f) The retightening of the flange connections shall be repeated regularly in accordance with
point 4.2 c).
g) If there are leakages at the flange connections the tube bundle heat exchanger must be shut
the bolts shall be carried out cross wise and clockwise progressing over the whole
circumference. In no case must be retightened only the bolts in the direct proximity of the
leakages. A pressurization is admissible only when all screws are integrated and tightened. If
leak-tightness is not achieved, the sealing shall be replaced. The shutdown shall be effected
according to point 5.1.
h) In accordance with the operator instructions overhaul periods shall be determined. In this
context corrosion and contamination of the tube bundle heat exchanger shall be inspected.
i) An efficiency drop (deterioration of the heat transfer, increase in pressure loss) points to an
increasing contamination of the flow paths. For this reason a duly cleaning is necessary. The
complete blockage of the tube bundle heat exchanger must absolutely be prevented, because
it would not only make cleaning significantly more difficult, but would also cause a direct
danger for the tube bundle heat exchanger. Contaminations may cause different thermal
expansion of individual tubes which may result in inadmissible thermal stresses with
subsequent tube damages.
j) The tube bundle heat exchanger is always operated as part of a complete plant and not
independently. Remarks and requirements related to the operation as well as faulty usage or
faulty operation by the personnel should be indicated within the overall operation manual of
the plant.

4.4 Troubleshooting
a) Critical malfunctions/mistakes made by the personnel:

- Operation of the apparatus by untrained personnel or personnel which does not meet the
provision according to point 1.2.2
- Non-compliance with the installation instructions (point 2), the start-up measures (point 4)
and the repair work/maintenance instructions (point 5)
- Tightening of the screwing of both of the saddle bearings (heat-related expansion of the
gas cooler must be ensured)
- Faulty connection of the apparatus to the tube lines
- Operation of the apparatus beyond the given technical data (see point 3)
b) Actions to be taken in the case of malfunction/disaster:

- In all cases of malfunction the shutdown (according to point 5.1) of the apparatus, a
troubleshooting and a fault correction become necessary, e. g.:
1) in the case of a pressure increase beyond the maximum value stated in point 3
with no pressure reduction possible to carry out by the operator
2) upon failure of a safety valve
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3) upon signs of fatigue of the material of the main components (e. g. cracks, dents,
failure of the sealing, leaky welding seams)
4) upon erroneous function of measuring instruments
- Maintenance and repair works on a pressurized apparatus are not allowed
- Leakage on connections/flange connections because of:
1) defect seals, flange, flange sealing surface, flange connection
2) fatigue of material
3) inadmissible tensions/forces
 check/tighten flange connection

 check tube line system for undesirable tensions/forces
 check/clean replace seals
 observance of point 5
- Increased loss of power because of:
1) Failure in the complete plant
2) Quality of the medium
3) Foreign objects/accumulations in the tube lines

 inspection of the complete plant + correction of faults
 inspection of the quality of the medium + maybe clean/ filter/replace the
medium
 opening and cleaning of the apparatus (according to point 5.3)

5 Repair Work and Maintenance Instructions
5.1 Shutdown
a) Tube bundle heat exchanger with fixed bundle and respectively with stuffing box:
When shutting down, the shell side is to be shut down after the tube side.
Tube bundle heat exchangers with floating head and U tube bundle:
First, shut down the warmer medium, irrespective of shell side or tube side.
b) The tube bundle heat exchanger shall be depressurized; it must be in a pressure-less state.
The internal temperature shall be lowered to a temperature at which no danger may arise.
The tube bundle heat exchanger must be reliably disconnected from all systems (e. g. set
blanking plates) and if necessary it must be damped and rendered inert.
c) Via the drain openings (see drawings) the medium shall be removed completely from the
tube bundle heat exchanger. To this end, the venting hole (per room) at the highest point
must be opened in order to prevent the creation of underpressure within the tube bundle heat
exchanger when the medium runs off. In the case of products dangerous to health and
explosive products the container must be rinsed in accordance with the legal requirements.
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Only then the bolts of the flange connections may be untightened.

d) The complete draining should also be carried out when the tube bundle heat exchanger shall
be shut down, but not opened, for a longer period of time. This prevents for example the risk
of corrosion and/or damage due to frost.
e) In the case of a longer shutdown it is advisable to preserve the machine by means of a
nitrogen filling (at an overpressure of 0.5 bar(g)) and to mark it in an appropriate manner.
But prior to that, the tube bundle heat exchanger must be completely drained and dried. The
drying may be carried out by means of evacuation or sparging with dry air. This action needs
to be pursued until the relative air humidity at the outlet-side is 30% related to 20 °C. The
check for the residual moisture in the apparatus may be carried out by means of a dew point
measurement (minus 10 °C). If there is no cooling water recirculation the cooler must be
completely drained, dried and preserved in an appropriate way. There is also the possibility
of a chemical stoppage preservation.
5.2 Disassembly
a) Prior to any disassembly it shall be checked if all spare parts such as spare seals are
available. Spare seals shall be ordered from the manufacturer in due time.
b) The slinging for the disassembly shall be carried out at the attachments points and the sling-
ing scheme provided for this purpose. The stated maximum load capacity of the supporting
elements must not be exceeded. The required indications are stated in the drawing. When us-
ing carrying devices such as belt straps the corresponding safety regulations and guidelines
of the country in which the apparatus is installed shall be observed. During the disassembly
care shall be taken to ensure that no damage of nozzles, nozzle sealing surfaces or other at-
tachment parts occurs.

c) In the case of tube bundle heat exchangers that are arranged one upon the other (block or
battery construction) the pulling of the tube bundle of the upper tube bundle heat exchanger
may take place only after the disassembly of the block/battery und after the mounting of the
single tube bundle heat exchanger on an appropriate working surface.
d) The pulling of removable tube bundles shall be carried out in compliance with the safety
provisions. Prior to the pulling of the tube bundle, the following steps must be performed and
controlled:
1. Shell side drained and depressurized.

2. Loosen and remove all connections which are opposed to the tube pulling.
3. If existent, the intermediate ring/the stuffing box and their corresponding seals shall be
loosened and disassembled.
e) In order to avoid damages the bundle shall be lifted only at the points provided for that
purpose (e. g. lifting hooks) and by means of suitable auxiliary means (load bearing layers)
as well as without any diagonal pull. For taking up the tube bundle that had been pulled out
suitable supports shall be provided in order to prevent the bending of installed equipment (e.
g. transverse baffles and supporting plates, support grids and brackets).
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f) The transmission of the pulling and pushing forces for the pulling and the insertion of the
bundle shall be carried out with the utmost caution at the devices provided for that purpose
(drawbar eyes or cleats).
g) When dealing with tube bundle heat exchangers with internal coating the damage of the
coating shall be prevented. Destroyed coatings shall be removed immediately in accordance
with the provision of coating manufacturer.
h) Inlet and outlet chambers and covers are removed from the housing (by using the forcing
screw if available) and they shall be placed on a suitable surface.
5.3 Cleaning
a) Prior to the cleaning of the tube bundle heat exchangers they shall be depressurized, drained,
reliably disconnected from all systems (e. g. set blanking plates) and if necessary be damped
and rendered inert. Observe point 4.1.
b) For the cleaning of the tube bundle heat exchangers the use of substances/media that damage
the material is not allowed. Mordants are inadmissible.
c) When cleaning the tube bundle heat exchangers the applicable safety provisions for the use
of the cleaning materials shall be observed.
d) Attention! All sealing surfaces shall be perfectly cleaned.
e) The cleaning of tube bundle heat exchangers with fixed bundle by means of damping is only
admissible if this operation mode has been notified to the manufacturer of the apparatus
within the order. Otherwise, the manufacturer shall be consulted in writing prior to this
procedure.

f) The connecting tube lines to the draining and venting nozzles as well as these nozzles and the
nozzles with blind flange shall be cleaned. Afterwards the nozzles shall be reclosed and the
connecting tube lines shall be reinstalled.

g) When dealing with tube bundle heat exchangers with internal coating the indications of the
coating manufacturer shall be observed (see annexe if available).
h) If the tube bundle is connected to the shell/chamber by additional screws, collar screws or
other auxiliary equipment, the operator must ensure the pressure-less state of both pressure
chambers.
A cleaning by rinsing shall takes place under pressure. This is only admissible when all
screws are integrated and tightened.
i) Chlorides reduce the corrosion resistance of chrome-nickel steels and of chrome-nickel-
molybdenum steels (also Hastelloy, Incoloy, Inconel)! The effect of the chlorides depends on
concentration, temperature and pH value of the medium.
5.4 Maintenance
a) In accordance with the legal provisions for pressure equipment and the competent
surveillance authority overhaul periods shall be determined. In this context shall be checked
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for instance the leak tightness, the corrosion damage and, in the case of efficiency drop, the
contamination within the tube bundle heat exchanger.
b) The tube bundle heat exchangers are generally maintenance-free. However, we recommend
to the operator to regularly check the flange connections for leak tightness. In the case of
aggressive and dangerous media as well as when there are frequent load changes the time
intervals should be reduced after the first start-up, after the re-start after longer stoppage and
after instable system conditions.
j) Maintenance and repair works are not permitted on a pressurized tube bundle heat exchanger.

5.5 Options of Repair

a) Defect seals:
At the opened flange connections the sealing surfaces shall be cleaned and possible damages
shall be eliminated before the installation of new seals is carried out. The installation of seals
must be carried out with the utmost care. After the renewal of the seals, the flange
connections shall be equipped with the number of bolts indicated on the drawing and shall be
tightened according to the bolt tightening torques (see drawing) cross wise and clockwise
progressing over the whole circumference. The thread of the bolts and nuts shall be treated
with an appropriate lubricant (see drawing).
b) Leaky inner tubes:
Should a heat exchange tube become leaky because of unexpected influences, the repair
technology shall be agreed with the manufacturer prior to such a repair or another repair (e.
g. replacement of inner tubes).
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5.6 Reassembly / Pressure Test
a) The transport of the parts of tube bundle heat exchangers takes place by means of the
intended supporting elements.
b) The insertion of bundles into tube bundle heat exchangers of block/battery construction must
only be carried out as single tube bundle heat exchanger on a suitable working surface,
unless another technical solution has been agreed.
c) The transmission of the pulling and pushing forces for the insertion of the bundle shall be
carried out with the utmost caution at the devices provided for that purpose (drawbar eyes or
cleats).
d) For the fastening and the horizontal mounting of the chambers 3 bolts for each with one nut
(from the flange connection fasteners) shall be arranged at equal distances at the housing
flange. The threads of the bolts and nuts shall be treated with an appropriate lubricant.
e) Prior to the reinstallation and after having cleaned the sealing surfaces and eliminated
possible damages the flange connections shall be equipped with new seals. The replacement
of the seals shall be carried out with the utmost care.
f) The threads of the bolts and nuts shall be treated with an appropriate lubricant. All apparatus
flange screw connections shall be tightened steadily cross wise and clockwise progressing
over the whole circumference. The tightening takes place in 3 steps. Lubricants and
tightening torques see drawing.
g) After the installation has been effected the tube bundle heat exchangers shall be tested in a
pressure test. This pressure test is performed as indicated in the drawings.
- In the case of the pressure test with water the pressure chambers shall be vented
completely. The pressure test shall be recorded; see point 6.3. The quality of the test
medium shall comply with the respective operator specifications. If the test water
quality is not specified by the operator, for the tube bundle heat exchangers made of

stainless steel a maximum chloride content of ≤ 20ppm shall apply and for C-steel
apparatus no restrictions are necessary in relation to the water quality.
- For the pressure test with gas the respective applicable safety provisions are to be
observed.
h) After the end of the pressure test with water and no immediate restart, the equipment must be
dried by means of evacuation our sparging with dry air. This action needs to be pursued until
the relative air humidity at the outlet-side is 30% related to 20 °C. The check for the residual
moisture in the apparatus may be carried out by means of a dew point measurement (minus
10 °C).
i) During the start-up and the performance of pressure tests the pressures and temperatures
indicated on the factory nameplate and on the drawings shall be observed and not be
exceeded.
j) In the case of pressure tests with water carried out at a temperature below 0 °C it must be
ensured that the water in the apparatus and in the measuring instruments does not freeze.
Point f) shall be observed.
5.7 Restart
zu Schadenersatz.
see chapter 4.2
5.8 Operation
see chapter 4.3

5.9 Spare and Wear Parts
If spare and wear parts are included in the delivery they will be supplied in a separate package or
in the package of the main equipment. If spare and wear parts are not included in the delivery
they may be ordered from the manufacturer as needed. Care shall be taken to ensure that during
the transport, storage and installation no damage may occur due to external influences (see also
point 2.4).

The copying, distribution and utilization of this document as well as the communi- Weitergabe sowie Vervielfältigung dieses Dokuments, Verwertung und Mitteilung seines
cation of its contents to others without expressed authorization is prohibited. Of- Inhalts sind verboten, soweit nicht ausdrücklich gestattet. Zuwiderhandlungen verpflichten
fenders will be held liable for the payment of damages. zu Schadenersatz.
E-mail:
Telefax:
Internet:
Address:
5.10 Service AEL
Germany
www.ael.de
[email protected]
Telephone: +49 34321 61-0
D-04703 Leisnig
Döbelner Straße 9
+49 34321 61-118

General Operation and Maintenance Manual
Rev. 0
Page 23 / 24
6 Annexes
6.1 Annexe 1: Forms for the Recording Repeated Pressure Test
Denomination: Gland Steam Condenser

Project: TIMOR 2
Customers order No.: B220-18215-3512
AEL job No.: 3120003
AEL drawing No.: 65-2433X
Ident No.: 1203.100596
shell side tube side shell side tube side

test pressure (bar Ü)
temperature test medium (°C)
test medium
quality of the test medium

zu Schadenersatz.
according to point 5.1 has been

observed
manometer No. with calibration

certificate
record of the pressure recorder

pressure test performed by:
results of the pressure test

date
stamp & signature

7. Radial Ventilator
7. radial fan

Commission-N°:
7001021687
Factory-N°:
4020005 Project:
TIMOR 2
Drawing-N°:
BB2285B
Baujahr: Pos.-Nr.:
Komponente: Ventilatoren 12MAM65AN110

component: Fans 12MAM65AN120
Einbauerklärung unvollständige Maschine

1.
Datenblatt Drehstrom-Käfigläufermotoren 1CV3083A
2.
Data sheet for three-phase Squirrel-Cage-Motors 1CV3083A
Montageanleitung
3.
Intsallation instruction
Ersatzteilliste
4.
spare part list
Karl Klein Ventilatorenbau GmbH
Waldstrasse 24
D-73773 Aichwald

According to Directive 2006/42/EC, Annex II part 1 B
This is to declare that the products:

Radial fans, Types: EEG... / DEG... / ENG... / DNG... / EMV... / DMV ... / EMVL.../
DMVL ... / ESV… / DSV… / EHV… / DHV…, all from year of manufacture 2010 on,
NHV... / MHV... / HHV... / MVG... / TVG... / HF... / PF..., all from year of manufacture 2012 on,
FLN... from year of manufature 2019 on
as far as possible regarding our scope of delivery, generally comply with the directives as follows:
Council Directive 2006/42/EC (Machine Directive)
Furthermore effectual directives:
The safety objectives of the low voltage directive (2014/35/EC), accordingly annex I, No. 1.5.1 of the machine
directive 2006/42/EC are fulfilled.
Note: For ATEX- types only exists a separate EC-Declaration of Conformity according ATEX Directive.
Note: There are separate declarations of conformity of the manufacturers for the electrical components.
Following harmonized standards were applied:

EN ISO 12100:2010
EN 15085-2…-5:2007 Railway applications - Welding of railway vehicles and components – Certification degree CL2.
Information: EN 15085 part 2 to 5:2007 ist maintained if it is aggreed with an order only.
We furthermore declare, that the special technical documents for partly completed machinery were prepared
according appendix VII part B and we commit to deliver these documents on demand to the commercial supervisory
authorities.
Note: Initial operation of the incomplete machinery is prohibited as long as it is not installed into a
complete machine which complies with the Council Directive 2006/42/EC and as long as the
appropriate Declaration of Conformity according annex II A is not on hand.
The authorized person for the compilation of the technical documents is the subscriber.
City / date Signature and functioning of subscriber
Aichwald, july, 12th 2019 Siegfried Seidler, Technical Manager
Annex
Followed Requirements of the annex I of 2006/42/EC. The figures are refering to paragraphs of
annex I: 1.1.2, 1.1.3, 1.3.4, 1.7.4.2 (partly)
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Manufacturer: Karl Klein

Ventilatorenbau GmbH
Waldstr.24 D-73773 Aichwald
Tel.: +49-711-369060 Fax: +49-711-36906950

E-mail: [email protected] http: //www.karl-klein.de
Fan type: MVG

up to 200°C
TVG for conveying particles in gaseous

media
up to 120°C

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MVGR with belt drive

up to 200°C

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MVGK with coupling drive

up to 350°C

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General conditions for the use of Karl Klein fans

These general conditions set out the basic rules for the proper use of the fans. Where necessary
they are supplemented by the information and specifications provided in the Installation
instruction. The individual conditions are as follows:
 All maintenance instructions must be observed.

 All safety devices must be correctly installed.
 Changes to factory settings are not permitted without our approval.
 Only lubricants specified by the factory, or equivalent, may be used. Contamination is not permitted.
 If the machines are installed in a fixed position, the foundations must be expertly produced in accordance with DIN 4024, Part
2, and the machine secured in accordance with our recommendations.
 Reactive forces associated with connection of pipe lines must be restricted to a minimum, for example by using compensators.
Where maximum loads for nozzles are specified in the dimension sheet, these must never be exceeded.
 No liability will be accepted for faults caused by inexpert placing into operation by the customer.
 Exceeding the maximum temperatures and speeds given in the specifications is not permitted even briefly.
 Foreign bodies are not permitted to enter the impeller.
 Only the substances (gas compositions) specified in the order are permitted to be conveyed. Any damages caused by non-
specified media compositions are excluded from the warranty agreement.
 The fans may only be operated in a smooth-running condition. The permissible levels of bearing vibration are defined by the
alarm and shut-down values specified in the Installation instruction.
 The alarm and shut-down functions on fans with vibration monitors must be in accordance with the limits specified in the
Installation instruction. Operation above the alarm value is only permitted on a temporary basis for analysing the cause of
vibrations. If the vibration values suddenly change for the worse, this may be a sign that the machine or part of the machine
is at imminent risk of failure, jeopardising operational safety in the process. The causes have to be determined immediately
and remedial action taken accordingly.
 Operation of the fans without vibration monitors is only permissible if the vibration levels do not exceed the limit values given
in the Installation instruction (if no information is provided, 7.1 mm/s for fixed installation according to ISO 14694 BV-3; 4.5
mm/s for fixed installation according to ISO 14694 BV-4).
 Modifications to the impellers in connection with operational balancing of the customer have to be agreed with us. Any
unauthorised measures shall render the warranty void.
 System-related swirling of the gas flow in the direction of rotation of the impeller must be prevented; counter-swirling is not
permitted.
 Continuous operation is only permitted for the operating points specified in the order confirmation; in particular, operation with
a closed slide valve or closed flow restrictor is only permitted for a short time (max. 5 minutes for start-up assistance).
 For fans with vane controllers, all fan controller positions require approval for operation, with the exception of a closed vane
controller (90° or 0%). Operation with a closed vane controller is only permissible during start-up. The vane controller must be
opened quickly as soon as the final speed has been reached. For applications with pressure increases in excess of 10kPa,
the permissible vane controller positions in continuous operation must be restricted to a maximum of 70°.
 It is essential that the flow rate never falls below a minimum flow rate Vmin = 0.3 * Vopt in continuous operation; for pressure
increases greater than 20 kPa the minimum flow rate has to be raised to 0.5 * V opt and operating points with pressure increases
of less than 40% of the pressure increase in the design point have to be blocked.
 In the case of free intake, the inflow to the fan must be unimpeded. The minimum dimensions of the unimpeded rectangular
space around the centre-point of the intake opening is a = b = 2.5 * d (d = intake diameter).
 Heavy caking, corrosion and visible wear on impellers are inadmissible. Prevention measures must be agreed with us
immediately.
 The surge-like entry of liquids into the impeller and inadequate removal of condensation from the fan housing must be
prevented under all circumstances.
 If the motor is provided by the customer, we do not provide a warranty for design and function or for the operational safety of
the coupling drive/belt drive in the event of electrical malfunctions (according to VDI 3840).
 The fans may only be started up when the machine is at a standstill.
 Where process temperatures are over 140°C, the fan is not permitted to be at a standstill because this may lead to damage
to the bearings.
 Temperature gradients of more than 50°C/min are inadmissible, unless agreed otherwise.
 If fans are operated in parallel, operation to the left of the peak of the characteristic curve must be blocked.

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Transfer of PILLER housing positions to Karl-Klein housing positions

Clockwise (facing motor) Anti-clockwise (facing intake)
L0 L315 L270 L225 L180 L90 L45

Anti-clockwise (facing motor) Clockwise (facing intake)
R0 R315 R270 R225 R180 R90 R45

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Table of contents
1 GENERAL INFORMATION............................................................. 9
1.1 General description ....................................................................................... 9
1.2 Intended use .................................................................................................... 9
1.3 Declaration of incorporation of partly completed machinery ...................... 9
2 SAFETY INFORMATION .............................................................. 11
2.1 Symbols ......................................................................................................... 11
3 LIMIT VALUES ............................................................................. 14
4 NOTES AND INSTRUCTIONS ON SAFETY ................................ 14
4.1 Basic safety information............................................................................... 14
4.2 General notes and instructions on safety ................................................... 14
5 SPECIALISTS ............................................................................... 16
6 ELECTRICAL CONNECTION CONDITIONS ............................... 16
7 WARNINGS, LABELS .................................................................. 16
8 RESIDUAL RISKS ........................................................................ 17
8.1 Overview of hazards ..................................................................................... 17
9 DESCRIPTION OF THE PRODUCT ............................................. 19
9.1 Motor .............................................................................................................. 19
9.2 Housing ......................................................................................................... 21
9.3 Impeller .......................................................................................................... 21
9.4 Seal at the shaft exit ..................................................................................... 21
9.4.1 MVGR fans ..................................................................................................... 21
9.4.1.1 Belt drive ................................................................................................... 21
9.4.2 MVGK fans ..................................................................................................... 21
9.4.2.1 Coupling .................................................................................................... 22
9.4.2.2 Cooling impeller ........................................................................................ 22
10 ITEMS SUPPLIED AND TEMPORARY STORAGE ...................... 23
11 INFORMATION ON TRANSPORTATION..................................... 23
11.1 Safety information for transportation .......................................................... 23
11.2 Transport instructions .................................................................................. 23
11.2.1 MVGK fans ..................................................................................................... 24
12 INSTALLATION ............................................................................ 26
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13 PLACING INTO OPERATION / TEST RUN .................................. 27

14 SWITCHING ON THE FAN ........................................................... 28
15 SWITCHING OFF THE FAN ......................................................... 28
16 SERVICING AND MAINTENANCE ............................................... 29
16.1 MVG fans ....................................................................................................... 30
16.1.1 Motor............................................................................................................... 30
16.1.2 Housing........................................................................................................... 30
16.1.3 Impeller ........................................................................................................... 31
16.1.4 Shaft seal ........................................................................................................ 31
16.1.9 Removal of protection against corrosion ......................................................... 32
16.2 MVGR fans ..................................................................................................... 33
16.2.1 Motor............................................................................................................... 33
16.2.2 Housing........................................................................................................... 33
16.2.3 Impeller ........................................................................................................... 33
16.2.4 Shaft seal ........................................................................................................ 33
16.2.5 Bearing ........................................................................................................... 33
16.2.6 Belt drive ......................................................................................................... 33
16.2.10 Storage and corrosion protection instructions ............................................. 35
16.3 MVGK fans ..................................................................................................... 36
16.3.1 Motor............................................................................................................... 36
16.3.2 Housing........................................................................................................... 36
16.3.3 Impeller ........................................................................................................... 36
16.3.4 Bearing ........................................................................................................... 36
16.3.5 Shaft seal ........................................................................................................ 36
16.3.6 Coupling drive ................................................................................................. 37
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16.3.11 Tightening torque ........................................................................................ 38
16.4 MVGK fans ..................................................................................................... 41
16.5 MVGR fans ..................................................................................................... 41
17 DISASSEMBLY ............................................................................ 43
18 DISPOSAL .................................................................................... 43
19 SPARE PARTS ............................................................................. 44
20 DECLARATION OF INCORPORATION OF PARTLY
COMPLETED MACHINERY ......................................................... 49

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1 General Information
1.1 General description

The partly completed machine described in this Installation instruction is a cast radial fan.
The term radial fan refers to machines use to convey air, air-like gases or gas mixtures. Radial fans operate on the basis
of centrifugal force. The air therefore flows into the fan parallel to the axis of rotation, but is then deflected at right-angles
before it enters the impeller and is thrown out to the outside by centrifugal force. The term radial fan is derived from the
fact that the medium moves on a radius of the impeller after it has been deflected.
The fan is normally comprised of the following components:
- Housing with openings on the intake and pressure sides
- Impeller in a housing, mounted on a shaft
- Stand, which supports the housing, bearing unit and drive unit (motor)
- As a general rule, pipe lines supplied by the customer and fitted to the openings on the intake and pressure
sides
A fan in the case of the present application is a flow machine which is subjected to high dynamic loads
and may only be operated by qualified personnel!
1.2 Intended use

The fan is designed exclusively for conveying the medium specified in the data sheet/order documents for the machine,
and subject to the operational parameters specified therein. Any use beyond the aforementioned use and any deviation
from the operational parameters which exceeds the general safety instructions, shall be regarded as improper use. The
manufacturer shall not be liable for any damages resulting from such improper use. In this case the risk is borne solely
by the user.
The definition of intended use also encompasses observing the operating, maintenance and servicing conditions
specified by the manufacturer.
The fan may only be operated, serviced and repaired by persons who are familiar with it and have been informed about
its potential hazards.
The applicable accident prevention regulations and all other generally recognised rules relating to health and safety at
work and road traffic must be complied with.
The manufacturer will not be liable for any damages resulting from unauthorised modifications to the machine.
1.3 Declaration of incorporation of partly completed machinery

The fan described in this Installation instruction conforms with the safety and health requirements of European Machinery
Directive 2006/42/EC. If properly installed and maintained and used in accordance with the intended use it will not
compromise the health or safety of persons or the safety of property.

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It is essential that you read the "Safety instructions" chapter in this Installation instruction
before placing the fan into operation.
Before placing the fan into operation for the first time and each time it is started up again
after inspection and maintenance work, it has to be ensured that all foreign bodies, tools,
scaffolding and auxiliary equipment have been cleared from the fan housing and
downstream ducts.
All safety equipment such as emergency stop switches, shaft protection, coupling
protection, etc., must be installed.
Cordon off the fan's danger zone to unauthorised persons over a wide area and switch on
the fan from a safe distance.
.
Persons, animals or loose objects must never be allowed to stand in the air flow or be
suctioned in!
The air flow generated by the fan can be so powerful that it is capable of sucking in or
blowing away a human body or heavy objects.
It is imperative that all supplied and agreed/provided safety devices such as temperature,
vibration and speed monitors, etc., are connected and also checked to ensure that they
are in perfect working order at all times.

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2 Safety information
2.1 Symbols
Symbols are used in this Installation instruction and on the fan which must be given special attention:
This draws attention to hazardous situations involving a risk of personal injury and damage to property.
Risk of danger from electricity. Work to be carried out may only be carried out by an electrician.
Information relating to protection of the environment
Beware of risk of injuries to hands
Beware of suspended loads
Beware of hot surfaces
Beware of rotating parts
Beware of caustic substances
Beware of fall hazard
Beware of harmful substances
Beware of potentially explosive atmosphere

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Beware of toxic substances
Slinging points for transporting the fan
Centre of gravity of the fan
Manual arc welding prohibited on the fan
No access for persons
Read this Installation instruction before placing into operation
Wear ear protection

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MANDATORY REQUIREMENT Observe instructions!

It is imperative that the specified safety instructions must be observed.

Ear protection must be worn for all work on the system.



Safety glasses must be worn for all work on the system.

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3 Limit values
Limits for which operation of the fan must be stopped:
MACHINE VIBRATIONS
Measured at the bearing points
Alarm:  7.1 mm/s (Check the fan as quickly as possible)
Shut-down:  9.0 mm/s (The fan must be switched off immediately)
MEDIUM TEMPERATURES
With Felt-ring-sealing -15 up to +120 °C
With Coal-swim-ring-sealing -15 up to +200 °C
MVGR, MVGK
BEARING TEMPERATURES
Alarm  90°C (The fan can continue to be operated)
Shut-down  100°C (The fan must be switched off immediately)
4 Notes and instructions on safety
4.1 Basic safety information

The fan has been constructed in accordance with the latest state-of-the-art in technology and approved technical rules
concerned with safety. Nevertheless, it may still be a source of danger to the life and limb of the operator or other persons
during operation, or of impairment to the machine and other items of property.
The fan must only ever be used in perfect technical condition, in accordance with the intended use and with proper regard
for safety and dangers and the instructions in the Installation instruction. In particular, any faults which compromise safety
must be eliminated immediately.
4.2 General notes and instructions on safety

4.2.1 In addition to observing the notes and instructions contained in this Installation instruction, you must also observe the
general regulations concerned with safety and the prevention of accidents.
4.2.2 The owner-user is responsible for ensuring that the machine is only used when it is in perfect working order.
4.2.3 Changes to factory settings are not permitted without our approval!
4.2.4 The fans may only be started up when the machine is at a standstill.
4.2.5 Exceeding the maximum temperatures and speeds given in the data sheet is not permitted even briefly!
4.2.6 Before connecting up the electrical connections of the motor, the manufacturer's instructions relating to safety and
commissioning and the requirements of DIN VDE 0105 or IEC 364 must be taken into account!
4.2.7 Modifications to the impellers in connection with operational balancing of the customer have to be agreed with us.
4.2.8 It must be ensured that fluids or dissimilar materials are prevented from getting into the fan to the extent that they can be
conveyed by the impeller! If any fluids are conveyed, this will damage the impeller beyond repair! Provision must be
made to ensure that condensate is effectively removed from the fan housing!
4.2.9 Caking, corrosion and visible wear on impellers are inadmissible! Prevention measures must be agreed with us
immediately!
4.2.10 System-related swirling of the gas flow in the direction of rotation of the impeller must be prevented; counter-swirling is
not permitted!
4.2.11 It is essential that the flow rate never falls below a minimum flow rate Vmin = 0.3 * Vopt in continuous operation; for pressure
increases greater than 20 kPa the minimum flow rate has to be raised to 0.5 * V opt and operating points with pressure
increases of less than 40% of the pressure increase in the design point have to be blocked! The impeller will be damaged
beyond repair if the fan is operated for longer periods at below specified flow rates! Short operating states (start-up and
shut-down) of less than 5 minutes duration per day are permissible!

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4.2.12 The cleaning opening on the fan housing may only be opened when the machine is at a standstill! The fan must be
secured to prevent it starting up again during this time!
4.2.13 The fans may only be operated in a smooth-running condition. The permissible levels of bearing vibration are defined by
the specified alarm and shut-down values if vibration monitors are provided.
4.2.14 The alarm and shut-down functions must be in accordance with the limits specified in the Installation instruction.
Operation above the alarm value is only permitted on a temporary basis for analysing the cause of vibrations! If the
vibration values suddenly change for the worse, this may be a sign that the machine or part of the machine is at imminent
risk of failure, jeopardising operational safety in the process! The causes have to be determined immediately and remedial
action taken accordingly!
4.2.15 Operation of the fans without vibration monitors installed is only permissible if the vibration levels in the bearing planes
do not exceed a maximum value of 9.0 mm/s (ISO 14694 BV-3)! For an optimum machine service life, the maximum
vibration levels should be restricted to 7.1 mm/s! Process-relevant fans need to have their vibration levels checked and
documented at regular intervals (every 14 days as a minimum).
4.2.16 Fan components which may be touched accidentally during normal fan operation; drive or supply systems with an
external surface temperature of over 65°C or below minus 12.5°C must be protected, insulated or provided with warnings
(see DIN EN 563).
4.2.17 Electrical and mechanical safety equipment provided by the customer must comply with the requirements of DIN EN
60204-1, DIN EN ISO 13857 and DIN EN 349.
4.2.18 The build up of electric charges must be prevented by the earthing of components. In this regard, compliance with DIN
EN 50081 Parts 1 and 2 is required.
4.2.19 The pipe lines and the housing must be inspected at regular intervals to check for the presence of foreign bodies. These
must not be permitted to get into the inside of the fan.
4.2.20 The fan may only be operated with pipe lines connected or the use of mesh guards. Mesh guards in front of the intake
opening for free intake must not be capable of being removed using tools.
4.2.21 The fan must be examined for transport damage before it is placed into operation and must not be placed into operation
if there is any damage.
4.2.22 The machine may only be operated if guards are installed, using the original means of fastening.
4.2.23 Welding work on the fan is prohibited and will unavoidably render the warranty void.
4.2.24 If buffer gases are used on shaft exits, they must not be harmful. They must be compatible with the medium and must
not corrode, modify or break down any of the existing materials.
4.2.25 Controllers for speed-controlled drives have to be set so that there is no possibility of resonance with the resonant
frequencies of the mechanical system.
4.2.26 Guide mandrels must be used for installation and maintenance work.
4.2.27 Appropriate precautions must be taken against falling when carrying out maintenance and repair work.
4.2.28 Operation on a 60Hz mains system is not permitted for 50Hz machines.
4.2.29 To prevent electric shocks caused by contact with live parts, connect metal cable ducts and cable sheaths to the
protective conductor system.
4.2.30 The incoming feeder must be switched off automatically by overcurrent and earth-leakage circuit-breakers.
4.2.31 Incorrect displays and malfunctions on the monitoring and control systems caused by interference from electromagnetic
fields in the signal cable or power supply cables must be prevented by sufficient shielding, including in the control
cabinets.
4.2.32 It is imperative that ear protection be worn for noise emissions of 85 dB(A) and over.
4.2.33 The customer must provide adequate illumination for the work area for all maintenance and servicing work.
4.2.34 If operated on a frequency converter, the maximum speed must be locked.
4.2.35 An automatic restart after the power supply has been restored is inadmissible and must be prevented.
4.2.36 The customer must provide and use lockable central switches and install emergency stop switches.
4.2.37 Lubrication of the bearings must be ensured by strict observance of lubrication regulations and regular maintenance,
including checking the bearing temperatures.
4.2.38 Maintenance must be carried out at regular intervals in accordance with our Installation instruction!

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5 Specialists
The work of placing into operation may only be carried out by specialists who, on the basis of their professional training,
experience and instruction, have sufficient knowledge of:
- Directives, guidelines and generally recognised codes of practice -

- Safety regulations
- Accident prevention regulations
The specialists must:
- be assigned/contracted to do the work by the company;

- be capable of assessing the work they have been assigned/contracted to do;
- be capable of recognising and preventing or avoiding potential hazards;
- be authorised to undertake the necessary work and activities by the individual responsible for safety.
Only deploy reliable and trained personnel who have been familiarised with the work. Only qualified electricians
(according to the definition of specialists in DIN VDE 0105 and IEC 364) are permitted to carry out any work or checks
on electrical components!
This must be in compliance with the valid, applicable:
- national regulations;
- safety regulations;
- accident prevention regulations.
The applicable regulations (VDE, etc.) relating to the handling of electrical equipment, e.g.
- disconnection;
- securing to prevent equipment being switched on again;
- verifying that equipment is disconnected from the power supply;
- earthing and short-circuiting;
- covering or safeguarding of adjacent live components,
must be complied with.
Electricians are defined as persons who, on the basis of their professional training, experience and instruction, have
knowledge of the applicable standards, regulations and accident prevention regulations. They must also be capable of
assessing the work they have been assigned to do and recognising potential hazards.
6 Electrical connection conditions

For the connection of the electrical components, the valid, applicable national standards apply. In this connection it is
important to ensure that the regulations of the relevant power supply companies are also taken into account.
Only qualified electricians (according to the definition of specialists in DIN VDE 0105 and IEC 364) are
permitted to carry out any work or checks on electrical components!
7 Warnings, labels
All information signs affixed to the fan (such as slinging points, centre of gravity positions, direction of rotation arrows,
plus possible information relating to lubrication and belt drives) must be observed and kept in a legible condition.

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8 Residual risks
The residual risks listed below still remain in spite of the measures taken with regard to the integration of safety in the
design, and in spite of the safety precautions and the supplementary safety measures taken, and must therefore be given
special attention.
8.1 Overview of hazards

Crush injuries/damage due to Fatal injury, damage to Installation and Observe transport
falling parts / machines property assembly instructions
Shearing when installing Risk of injury Installation and Observe the Installation
machine components assembly instruction; use guide
mandrels
Drawing into the fan housing Fatal injury Intake opening Observe the Installation
instruction; observe
safety distances
Parts of the body and clothing Risk of injury, damage to All rotating parts Observe the Installation
getting drawn into the drive property instruction; do not
elements remove safety
equipment
Loss of stability Risk of injury, damage to Transportation and Observe the Installation
property operation instruction;
observe transport
instructions;
proper transportation;
proper foundations and
fastening
Slipping, falling Risk of injury Installation and Observe the Installation
assembly and instruction;
maintenance take appropriate
measures against falling
and crashing
Electric shock Fatal injury Direct danger from Observe the Installation
contact with live parts; instruction;
indirect danger from observe safety
faulty live parts regulations
Electric shock caused by Fatal injury Contact during Observe the Installation
electrostatic discharge operation instruction;
observe safety
regulations;
earth the housings
Burn or freezing injuries due to Risk of injury; Hot/cold machine Observe the Installation
hot/cold machine components Risk of explosion due to components instruction;
increased risk of ignition marking;
Loss of hearing or physiological Risk of injury Noise levels over 70 Observe the Installation
impairment due to machine dB(A) instruction;
noise marking;

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Danger due to materials and Risk of injury, damage to Installation, assembly, Observe the Installation
other substances property maintenance and instruction;
operation Prevent foreign bodies
from entering; provide
sufficient ventilation;
marking;
Wear safety equipment
Combination of hazards Risk of injury, fatal injury, Inexpert installation Observe the Installation
damage to property, harm and placing into instruction
to the environment operation; operating
errors
Unexpected start-up Fatal injury Maintenance, repair Observe the Installation
instruction;
observe safety
regulations; lockable
central switch
Escaping high-pressure fluid - Risk of injury Maintenance and Observe the Installation
buffer fluids on shaft seals operation instruction;
observe safety
regulations; limitation of
buffer fluid connection
pressure
Inadequate monitoring Risk of injury, damage to Operation Observe the Installation
property instruction;
observe safety
regulations;
connection and
activation of monitoring
functions
Impeller breakage, parts Risk of injury, fatal injury, Fan housing, Observe the Installation
catapulting out damage to property, harm operation instruction;
to the environment observe safety
regulations; proper use

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9 Description of the product
9.1 Motor
General information
There are live parts and rotating parts on the inside of the electric motors. All connection, commissioning and maintenance
work must therefore be carried out as a general rule by qualified specialists in accordance with the information and
specifications provided by the manufacturer. The requirements of DIN VDE 0105 or IEC 364 must be complied with. If
not, there is a risk of causing serious personal injury and damage to property. The valid, applicable national, local and
system-specific regulations and requirements must be observed.
Intended use
The motors have been designed in accordance with DIN VDE 0530.
The use of motors in potentially explosive areas falling under danger zone 1 is not permitted without certification of
conformity (observe supplementary instructions).
The power rating given for the motors is for ambient temperatures up to +40°C and for installation altitudes = 1000 m
above sea level. Use under other ambient conditions may be possible under certain circumstances subject to consultation
with the manufacturer of the motor or fan.
Electrical connection
Connection may only be carried out with the system disconnected from the power supply.
The system must be secured to prevent it being switched on again!
In particular, the fan must also be secured to prevent it being started up again accidentally!
The information on the rating plate, the connection diagram in the connection box and the additional information in the
Installation instruction of the manufacturer must be observed.
To ensure that the electrical connection provides lasting safety, the connection work must be carried out in accordance
with the motor manufacturer's Installation instruction.
Observe the tightening torques for the terminal board connections. These can be found in the motor manufacturer's
Installation instruction.
It must be ensured that neither foreign bodies and dirt or moisture get into the terminal box. Cable inlets which are not
required need to be sealed off with blank plugs to make them dust-tight and watertight. When you close the terminal box,
make sure that the seal on the cover of the terminal box is fitted correctly.
The mains voltage and mains frequency must be identical with the values given on the rating plates for the motor. Motors
with wide voltage winding can be operated with different mains voltages. In this case you have to check whether the
available mains voltage is covered by the voltage range given on the motor's rating plate. Where 60 Hz mains systems
are concerned, an additional plate may be attached by the fan manufacturer which tells you that the motor may also be
operated with 50 Hz on a 60 Hz mains system.

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The arrangement of the jumpers on the terminal board is dependent on the available mains voltage (see illustration).
Winding circuit in
Positions of the jumpers on the

terminal board
Two examples for winding constructions and operating voltages:


460 V 60 Hz /
220-240 V / 380-420 V 50 Hz
440-480 V 60 Hz

460 V / 60 Hz /
380-420 V / 660-725 V 50 Hz
440-480 V / 60 Hz
The protective earth conductor has to be connected to the

terminal.

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9.2 Housing
The grey cast iron housings can be rotated through 45 degrees. This means that other housing positions (except 225°)
can also be set retrospectively without changing the direction of rotation of the impeller.
If the direction of rotation is changed from anti-clockwise to clockwise or the reverse, the same housing parts can be
used. Only the intake-side housing and the motor stand have to be swapped over. Attention: The impeller has to be
replaced.
The condensate drainage nozzle (only provided if ordered) located is at the lowest point on the housing and is sealed
with a plug. Before placing into operation and during operation, the nozzle has to be opened if necessary to allow any
condensation which has collect to drain away. Never allow the impeller to start up in condensation as this could lead to
damage and unbalance.
The fan housings have a flange connection with threaded holes on the intake side and a connection flange with through
holes on the pressure side.
9.3 Impeller
The impeller of the MVG (heavy duty) design made of St 02 Z material is equipped with blades which are bent forwards
and which is mounted overhung on the motor shaft.
The impeller of the MVGR design made of St 02 Z material is equipped with blades which are bent backwards and
which is mounted overhung on the motor shaft.
The impeller of the MVGK design made of 1.0347 material is equipped with blades which are bent backwards and
which is mounted overhung on the fan shaft.
The maximum permissible speed (specified on the rating plate on the fan) must never be exceeded
under any circumstances!
9.4 Seal at the shaft exit
The housing is sealed at the shaft exit by a felt ring in the motor-side housing cover. Leakage losses should be low.
Version with a mechanical seal
The housing is sealed at the shaft exit by a mechanical seal. The mechanical seal is comprised of the seal face
compartment, compression spring, thrust ring, two O-rings and the seal face. The rotating seal face is pressed against
the sealing face of the vertical seal face compartment in the axial direction by the springs.
9.4.1 MVGR fans
9.4.1.1 Belt drive
The drive is provided by a V-rope drive. The belts are electrically conductive in accordance with ISO R 1813 and thermally
resistant from -55°C to +70°C.
 Before placing into operation, the V-belts have to be re-tensioned to the values given below (see chapter 16)!
 The V-belts have to be checked after a short running-in period of about 15 minutes and re-tensioned if necessary.
 Check the V-belt after 3 days and re-tension again if necessary, or even earlier depending on operating conditions.
 Check the V-belt after 10 days again, or even earlier depending on operating conditions.
 The belt tension needs to be checked at greater intervals on a regular basis.
A belt testing device must be used for testing and tensioning.
9.4.2 MVGK fans

The drive shaft is supported in roller bearings with grease valves in a bearing head which is flange-mounted on the fan
housing.
The fan shaft is supported by a double-bearing casing with grease lubrication. The fan shaft is supported at two bearing
points which are both mounted together in a single bearing casing.

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9.4.2.1 Coupling
The fan coupling compensates for radial, axial and angular shaft displacements between the fan and motor. The ring-
shaped rubber elements, which are subjected to tangential forces, transfer the torque.
Supplier : Flender
Coupling type : N-EUPEX
Coupling size : B 80
Ambient temperature (max.) : 80 [°C]
9.4.2.2 Cooling impeller

To dissipate the heat which is transferred from the fan by the shaft, a cooling impeller is clamped to the shaft behind the
shaft seal.
This cooling impeller is of multi-piece design. The shaft seal can be accessed by removing the cooling impeller.
For trouble-free operation, it is essential that the cooling impeller is tightly fastened. If it is not fastened
tightly enough, the cooling impeller could work loose and fly off, which could cause serious injuries!
For safety reasons the insulation provided by the customer must be installed before placing into
operation to ensure that the cooling impeller protection cannot be covered!

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10 Items supplied and temporary storage
Check the delivery for completeness in accordance with the delivery note when it arrives. Any missing parts and/or
transport damage must be reported immediately in writing.
The fan has to be protected against penetration by moisture and dust and against inadmissible vibrations from the
foundations. Measures must be taken to prevent the influence of strong fluctuations in temperature. Failure to observe
the above could lead to damage to electric motors, cable terminal boxes, bearings, coats of paint and seals, etc., as well
as corrosion, and therefore a higher risk of ignition as a consequence.
For temporary storage the fan must be stored in its transportation packing.
11 Information on transportation
The cast fans (MVG and TVG) do not have any slinging points on the fan housing. The eye-bolt on the motor must not
be used for transporting the fan as a complete unit. To transport the fan, a strap has to be wrapped around the motor
housing (between the drive side of the fan and the terminal box for the motor). The strap is prevented from slipping on
an axial basis by the terminal box.
The fan may only be lifted and transported by persons who have read this Installation instruction, have understood the
specified safety regulations, accident prevention regulations and instructions concerning the transportation of the fan,
and are familiar with the hoisting gear and required lifting tackle.
11.1 Safety information for transportation
Observe the safety information for transportation!
 Transportation and lifting on site is the responsibility of the customer and should be carried out by qualified
personnel.
 Accident prevention regulations must be complied with.
 Do not move the load over people.
 If the hoisting gear has sufficient load capacity, it can be used to lift the complete fan for transporting on site.
 Care must be taken when lifting the fan to ensure that no parts get damaged by the carrying ropes.
 Prevent the fan from bumping into anything, as this will case damage.
 The carrying ropes and harnesses must be suitable for the weight of the fan.
 Do not let the fibre ropes get tangled.
 Do not let ropes and chains get twisted.
 Suspension elements must be able to move freely on the load hook.
 Wear personal protective equipment (helmets, gloves, etc.).
 Transport eye-bolts on motors must not be used for lifting the fan as a complete unit.
 The fan has to be lifted and lowered gently in order to avoid causing any damage.
 The manufacturer cannot accept any liability for damages caused by transportation on site.
11.2 Transport instructions
Lift and transport the fan using suitable lifting tackle only!
lifting tackle!
 The cast fans (MVG and TVG) do not have any slinging points on the fan housing. The
eye-bolt on the motor must not be used for transporting the fan as a complete unit. To
transport the fan, a strap has to be wrapped around the motor housing (between the
drive side of the fan and the terminal box for the motor). The strap is prevented from
slipping on an axial basis by the terminal box.

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11.2.1 MVGK fans
Lift and transport the fan using suitable lifting tackle and slings only, at the transport eye-bolts
and/or lifting lugs intended for the purpose!
Observe the following diagram!
Permissible load directions

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 The fans may only be lifted and transported by the fixtures provided for the purpose. Do
not attach lifting tackle and slings to bearings, intake and pressure nozzles, motors or
other components!
 It is imperative that you make sure that you use lifting tackle and slings with the same
lengths and that the weight is distributed evenly. The angle must not exceed 25°! See
the previous diagram.
lifting tackle and slings. Use a carriage if necessary!

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12 Installation
 For outdoor installation, the installation phase itself and any repair work undertaken outdoors, suitable measures
must be taken to protect the fan against the elements.
 Check that the installation point is flat and clean.
 The installation tolerance for the alignment of the machine with
a greased bearing of max. 2 mm/m

must be observed.
 Immediate alignment is of critical importance to prevent damage to the bearings, vibrations and other defects!
 Strain on the fan at the connections caused by the pipe lines is not permitted and it is essential that this is prevented.
Strain could cause changes in the gap on the nozzle. This is likely to lead to rubbing of the impeller nozzle and
therefore an increased risk of explosion in explosive environments.
 If the machines are installed in a fixed position, the foundations must be expertly produced in accordance with DIN
4024, Part 2, and the machine secured in accordance with our recommendations. The requirements of DIN 18800
must be observed for all installations steel structures.
 Restoring forces from pipe lines must be restricted to a minimum, for example by using compensators. Where
maximum loads for nozzles are specified in the dimension sheet, these must never be exceeded. Pipe lines must
have specified fixed reference points.
This applies in particular to machines with media with a temperature over 100°C.
 The fan must be mounted on the foundations without strain.
 If installation is on vibration dampers, it is a requirement that compensators are fitted on the intake- and pressure-
side flange. This also applies to all other supply lines to the fan (condensate drainage nozzles, steam and oil supply
systems).
 Fasten vibration dampers at the intended points as shown in the installation layout drawing. If different types of
vibration damper are used, make sure that these are arranged in accordance with the installation layout drawing.
 If it emerges during installation that the machine has a slight tilt, an adjustment plate has to be fitted to the appropriate
vibration damper between the damper and the foundations.
 After completion of alignment, the dampers have to be secured to the foundations by screws or dowels. In certain
cases it will be sufficient if just the corner dampers are secured.
 The fan and motor must be properly and expertly earthed via the earth connections provided for the purpose.
 The fan components or supply systems must be capable of expanding freely in response to rising temperatures,
without coming into contact with combustible substances or materials.

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13 Placing into operation / test run
* No liability will be accepted for faults caused by inexpert placing into operation by the customer.
* Check whether lubricants have been filled up. The bearings must not be started without lubrication!
* Only specified lubricants, or equivalent, may be used. Contamination is not permitted.
* Before placing into operation, check that there are no foreign bodies in the pipe lines or the fan housing.
* Foreign bodies are not permitted to enter the impeller.
* The surge-like entry of liquids into the impeller and inadequate removal of condensation from the fan housing must
be prevented under all circumstances.
* Before the test run, check that the shaft is able to rotate easily and that the impeller moves freely (for explosion-
protected fans, check and document the impeller gap).
* Check the direction of rotation (there are direction arrows on the housing).
* Check that all mechanical and electrical safety equipment is properly fitted and installed.
* Check that the current type, voltage and frequency of the drive motor are suitable and that the connections have
been made in accordance with standards.
* Check that all guards have been correctly installed with original parts, including means of fastening.
* The materials and processing and operating materials used must be suitable for the intended use and must be
compatible with the medium.
Before it is placed into operation, the fan must be fitted with one or more EMERGENCY STOP command
devices for averting an immediate danger which has actually occurred or threatens to occur.
These devices must be clearly marked and must be accessible without difficulty at all times!
It must only be possible to release the EMERGENCY STOP command device by means of appropriate
actuation. This release function must not cause the fan to be restarted; it may only make it possible for
a restart to be carried out.

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14 Switching on the fan
The fan may only be started up if the moment of acceleration is sufficient over the entire start-up
range up to the rated speed!
Start up the fan with the flow restrictor closed.
Operation with a closed flow restrictor is only permissible during fan start-up. The flow restrictor
must be opened quickly as soon as the final speed has been reached!
Check the following points during and after the start-up of the fan:
* Power consumption
* Voltage
* Smooth running of the fan (vibrations)
* Unusual running noise
* Bearing temperatures
* Compression heat on the fan housing
If any of the specified values are exceeded or the fan makes unusual noises, switch off the fan
immediately and inform the manufacturer's service department.
15 Switching off the fan
Let the fan slow down to a stop without braking.
Observe safety regulations in accordance with DIN VDE 0105.
The fan must never be switched on again until the impeller has come to a complete standstill first.
This is the only way of preventing negative torque shocks which could cause considerable damage
to components such as bearings, impellers and couplings.
The fan is only permitted to be switched on and off by specialists who have been assigned to do so by the person
responsible for the system.

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16 Servicing and maintenance
Accident prevention regulations must be observed!
The usual mechanical engineering principles must be observed in relation to maintenance. Only suitably qualified
personnel are permitted to carry out any maintenance and repair work.
The customer must ensure that there is sufficient space available for maintenance and repair work. This applies both in
terms of service personnel and in terms of space for setting down parts of the fan such as impellers and the housing, etc.
Furthermore, constructional measures have to be provided to enable these parts to be lifted and moved, e.g. crane tracks
or beams for attaching chain hoists. The customer must also provide adequate lighting for servicing and maintenance
work, and must also take suitable measures to prevent falling. Guide mandrels are to be used for maintenance and repair
work.
Carry out maintenance and repair work using suitable protective equipment and tools only.

Ear protection may have to be worn for work on the system, depending on the surrounding noise
levels.



Safety glasses have to be worn for work on the system, depending on the specific activity.

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The fan needs to be checked every now and again for smooth running during operation. If the impeller does not run
smoothly, it needs to be cleaned and possibly rebalanced.
Before you open the fan housing, undo a flange connection or remove the mesh guard, the fan
must be switched off and measures taken to prevent it being switched on again. Make sure that
the impeller is at a standstill.
Verify that it is disconnected from the power supply. Cover or safeguard adjacent live
components.
Accident prevention regulations must be observed. All safety equipment must be re-installed
before the fan is switched on again!
Check that all hot surfaces have cooled down sufficiently!
Risk of burn injuries caused by removing insulation or opening service openings too quickly.
If the system is shut down for any lengthy period of time (longer than 3 months), the rotor unit needs to be
turned in 2-weekly cycles in order to ensure that the roller bearings are kept covered in lubricant and to prevent
point loading of the roller bearings!
Harmful and hazardous residual substances in the machine must be taken into account!
Use suitable cleaning agents and equipment for cleaning work!
The use of high-pressure steam cleaners for cleaning the fan is not permitted!
It is imperative that moisture is prevented from getting into components such as bearings and seals,
since this could lead to the development of corrosion.
After completion of maintenance and repair work, check that all solid and liquid foreign bodies have
been removed from the fan and adjacent system components, that all openings have been closed, and
that all mechanical and electrical safety equipment has been fitted back in place.
If any damage should occur in spite of observing all instructions and information, please report it immediately. The next
steps, subject to agreement:
* request for a service engineer, or

* repair or production of a new one at our factory
The following inspections and maintenance work need to be carried out in a general service:
16.1 MVG fans
16.1.1 Motor
must be observed!
16.1.2 Housing
* Damage / cracks!

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16.1.3 Impeller
* Wear
* Damage / cracks!
* Corrosion
* Temper colours
16.1.4 Shaft seal

* Dirt
* Wear

Quality 8.8
20 oC 100 oC 200 oC 250 oC 300 oC
Thread
M6 5930 8 5467 7 5004 7 4726 6 4448 6
M8 10848 19 10000 18 9153 16 8644 15 8136 14
M 10 17236 38 15889 35 14543 32 13735 30 12927 28
M 12 25094 65 23134 60 21173 55 19997 52 18821 49
M 16 47117 155 43436 143 39755 131 37546 124 35338 117
M 20 73527 303 67782 280 62038 256 58592 242 55145 228
M 24 105938 523 97662 482 89385 441 84420 417 79454 392
M 30 168874 1042 155681 960 142488 879 134572 830 126656 781
M 36 246420 1805 227169 1664 207917 1523 196366 1439 184815 1354
M 42 338576 2885 312125 2659 285673 2434 269803 2299 253932 2163
M 48 445342 4342 410550 3558 375757 3664 354882 3460 334006 3256



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corrosion.
No. 506.
materials.

* Denso tape
have to be removed.

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16.2 MVGR fans
16.2.1 Motor
must be observed!
16.2.2 Housing
* Damage / cracks!
16.2.3 Impeller
* Wear
* Damage / cracks!
* Corrosion
* Temper colours
16.2.4 Shaft seal

* Dirt
* Wear
16.2.5 Bearing
Type Amount of grease per bearing Re-lubrication interval [h]

[cm3]
MVGR 3 7-9 1000
MVGR 5 10 - 12 1000
MVGR 7 10 - 12 1000
Grease type: Shell Alvania RL3 or equivalent grease from another manufacturer.
16.2.6 Belt drive

Check the belt drive at regular intervals for:
* Wear
* Alignment
* Belt tension
If you need to re-tension or replace the belt, pay attention to the following:
1. Always replace the complete V-belt set, never just individual belts!
2. First slacken the belts, i.e. slacken the tensioning screws and the screws used to secure the motor. Shift the
motor sufficiently to allow the belts to be removed and fitted without tension.
3. Fit the new belt set and pre-tension slightly. Check the parallelism of the belt pulleys with a ruler and correct if
necessary.
4. The belts have to be tensioned enough for the specified thumb deflection depth to be achieved with the specified
test force. The values apply to the individual belt. Afterwards, tighten the screws for securing the motor. The V-
belts have to be re-tensioned after a running-in period of about 15 minutes. After three and ten days of operating
conditions, the V-belts need to be checked again and re-tensioned again if necessary. The belt tension needs to
be checked at greater intervals on a regular basis because slippage as a result of insufficient tension will lead to
the premature destruction of the belt.
5. A belt testing device from a belt manufacturer must be used for testing and
tensioning.

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Type Speed [rpm] Test force [N] Thumb deflection

depth [mm]
MVGR 3 4060 25 5,5
4640 25 5,5
5220 25 5,5
5800 25 5,5
6500 25 4,5
7250 25 4,0
MVGR 5 4060 25 5,5
4640 25 5,5
5220 25 5,5
5800 50 7,5
6500 50 6,5
MVGR 7 3620 25 7,5
4060 25 6,0
4640 50 8,0
5220 50 8,0
Table: Test force and thumb deflection depth in dependency on fan type and speed

Quality 8.8
20 oC 100 oC 200 oC 250 oC 300 oC
Thread
M6 5930 8 5467 7 5004 7 4726 6 4448 6
M8 10848 19 10000 18 9153 16 8644 15 8136 14
M 10 17236 38 15889 35 14543 32 13735 30 12927 28
M 12 25094 65 23134 60 21173 55 19997 52 18821 49
M 16 47117 155 43436 143 39755 131 37546 124 35338 117
M 20 73527 303 67782 280 62038 256 58592 242 55145 228
M 24 105938 523 97662 482 89385 441 84420 417 79454 392
M 30 168874 1042 155681 960 142488 879 134572 830 126656 781
M 36 246420 1805 227169 1664 207917 1523 196366 1439 184815 1354
M 42 338576 2885 312125 2659 285673 2434 269803 2299 253932 2163
M 48 445342 4342 410550 3558 375757 3664 354882 3460 334006 3256



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Karl Klein Ventilatorenbau GmbH does not specify any requirements as a general rule for corrosion protection for
temporary storage at the building site. The customer needs to take appropriate measures of protection to provide
protection against the elements.


* Apply a coating of oil-resistant lacquer to the insides of bearing housings and covers and grease slingers
corrosion.
No. 506.
* Corrosion protection must be applied to the profiles or mating surfaces of belt pulleys if machines with belt
drives are used.
materials.

* Denso tape
have to be removed.

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16.3 MVGK fans
16.3.1 Motor
must be observed!
16.3.2 Housing
 Damage / cracks!
Water collects in the bottom part of the housing when the impeller is cleaned and as a result of condensation. This water
has to be drained through the condensate drainage nozzle.
16.3.3 Impeller
* Wear
* Damage / cracks!
* Corrosion
* Temper colours
16.3.4 Bearing
Re-lubrication interval: Every 3,000 h (min. twice a year)
Grease type: Shell Alvania R3
Type Initial lubrication Re-lubrication

per bearing point [cm3] per bearing point [cm3]
MVGK 7 79 8
16.3.5 Shaft seal

Check the shaft seal (once a year) for:
* Dirt
* Wear or damage to the seal disc and the carbon ring
* Wear on the compression spring
Each shaft seal should be dismantled once a year during the fan inspection to enable the seal discs to be cleaned and
inspected.
The amount of wear permitted on the carbon ring is approx. 2.5 mm, as defined by the cylindrical part of the carbon ring.
When the conical part is reached, it is imperative that the carbon ring be replaced.

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16.3.6 Coupling drive

The manufacturer's Installation instruction must be observed!






 Take appropriate measures (cover with foil or store in solid buildings) to protect the fan against the elements
 Ensure that it is protected from rain and frost

 To prevent moisture and wetness infiltrating from behind or gap corrosion where weld seams are not
 The surfaces of shafts and shaft nuts made of normal steel which do not have a protective coating must

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 Apply a coating of oil-resistant lacquer to the insides of bearing housings and covers and grease slingers
 Bearings lubricated with oil must be filled to the overflow with corrosion protection oil, e.g. Anticorit OHK or
equivalent, and then the oil must be drained again after the machines have been raced a number of times
to produce a corrosion protection film.
 Shaft exits on bearings have to be wrapped with Denso tape (wax-soaked jute tape).
 Stuffing boxes and packings have to be wrapped with Denso tape (wax-soaked jute tape) on the outside.
corrosion.
 The housings of fitted labyrinth shaft seals must be treated with a long-term preservative such as Tectyl
No. 506.
 Shaft exits on shaft seals have to be wrapped with Denso tape (wax-soaked jute tape).
 Mechanically machined surfaces on impellers must be sealed with corrosion protection.
 Corrosion protection must be applied to impellers without paintwork or other form of coating.
 Corrosion protection must be applied to the profiles or mating surfaces of belt pulleys if machines with belt
drives are used.
 Corrosion protection wax must be applied to exposed bushes if they are made of non-rust-resistant
materials.
 Corrosion protection must be applied to the couplings on coupling machines.
 For coupling machines with hydraulic couplings, follow the supplier's instructions.
 For fans with vane controllers, throttle valves and adjusting devices, corrosion protection has to be applied
to the shaft exits of the blades and flaps and to the joints from both the inside and the outside. The
adjustment mechanism must not be blocked.
 For adjusting devices, follow the supplier's instructions.
 Gear units must be provided with protection against corrosion in accordance with the supplier's instructions.
In this connection, check the transmission oils used for compatibility with the residual corrosion protection.
 Motors must be provided with protection against corrosion in accordance with the supplier's instructions.
 The application of protective coatings with corrosion protection wax must be repeated.
 Bearings with oil lubrication need to be provided with fresh protection against corrosion.
 Denso tape which is in place must be pressed on again with no gaps after racing the machine.

 Denso tape
 corrosion protection wax on mating surfaces and, depending on the process conditions, on the process
have to be removed.
 Bearings with oil lubrication have to be flushed with the oil to be used later in order to eliminate any
possibility of contamination with corrosion protection oil. This is to be followed by filling with the stipulated
amount of oil.


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Quality 8.8
20 oC 100 oC 200 oC 250 oC 300 oC
Thread
M6 5930 8 5467 7 5004 7 4726 6 4448 6
M8 10848 19 10000 18 9153 16 8644 15 8136 14
M 10 17236 38 15889 35 14543 32 13735 30 12927 28
M 12 25094 65 23134 60 21173 55 19997 52 18821 49
M 16 47117 155 43436 143 39755 131 37546 124 35338 117
M 20 73527 303 67782 280 62038 256 58592 242 55145 228
M 24 105938 523 97662 482 89385 441 84420 417 79454 392
M 30 168874 1042 155681 960 142488 879 134572 830 126656 781
M 36 246420 1805 227169 1664 207917 1523 196366 1439 184815 1354
M 42 338576 2885 312125 2659 285673 2434 269803 2299 253932 2163
M 48 445342 4342 410550 3558 375757 3664 354882 3460 334006 3256

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Faults and troubleshooting
ATTENTION: The work described below must always be carried out by specialist personnel in compliance with
the applicable safety regulations. To prevent damage caused by work which is carried out inexpertly, you should
always have repair work carried out by our qualified specialist personnel.
Karl Klein Ventilatorenbau GmbH will not accept any warranty claims for damage caused by repair work carried
inexpertly.
The fan does not operate smoothly Caking on the impeller Clean the impeller.
Attention: Clean the impeller only
when it is at a standstill. The fan must
be secured to prevent it starting up
again during this time!
The impeller is worn. Replace the impeller.
The impeller has become deformed Replace the impeller.

as a result of thermal influences.
Strain on the fan as a result of Undo the foundation fasteners and

uneven foundations. level the foundations.
Secure the fan again afterwards.
Correct the settings.

Inexpertly adjusted/secured vibration
dampers.
Medium escaping from the shaft seal. The deal is faulty or worn. Replace the seal.
Grinding noises on the fan. Impeller rubbing against the intake Undo the housing cover and realign
nozzle. it; check the pipe line if necessary
and correct it.
Check the motor for bearing damage;

Noises from the motor. replace the bearing if necessary.
The power consumption given on the Excessive air flow. Reduce the air flow with the
rating plate is permanently exceeded. assistance of a flow restrictor until the
permissible power consumption level
is achieved.
Different speed for 60 Hz mains Check the frequency.

system.
The fan fails to start. The drive motor is not connected Check the connection.
correctly.
Reduce the switch-over time for star

With a star-delta starter, the motor to delta.
gets stuck in the star.
Close the flow restrictors.

Starts up against insufficient system
resistance.
The cross-sectional area of the cable
The motor safety device is too weak. and the safety equipment protect the
starting current during start-up.
Close the flow restrictors; check the

The start-up time is too long. torque MA/MN.
Check the motor and replace/repair if

The drive motor is faulty. necessary.

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16.4 MVGK fans
Bearing damage

lubricating.

clearance.

Coupling damage
Failure to operate smoothly The coupling halves are not aligned. Check the alignment in accordance
with the instructions of the coupling
manufacturer.
elements.
Elastic elements are too soft.
Use harder elastic coupling elements.

The motor torque is to high MA/MN elements.
Severe jolting during start-up Star-delta starter
16.5 MVGR fans
Bearing damage


lubricating.

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clearance.

Belt drive damage

Pronounced vibrations. The belt is too loose or too tight. Correct the tension of the belt.
Loud noises. Impeller rubbing against a nozzle. Correct the tension of the belt.
The belt is too loose or too tight. Correct the tension of the belt.
Incorrect belt selection. Replace the belt.
The belt is oily or dirty. Clean the belt or replace if

necessary.
The belt is worn.
Replace the belt.

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17 Disassembly
Disassembly of the fan to relocate it to a different installation location or if it is to be scrapped.
The disassembly of the fan may only be carried out by specialists who, on the basis of their professional training,
experience and instruction, have sufficient knowledge of safety regulations, accident prevention regulations and generally
recognised codes of practice (e.g. VDE guidelines, DIN standards). The specialists must be capable of assessing the
work they have been assigned to do, recognising and preventing potential hazards, and be authorised to undertake the
necessary work and activities by the individual responsible for the safety of the system.
18 Disposal
Parts and components of the fan which have reached the ends of their service lives, e.g. due to wear, corrosion,
mechanical strain, fatigue and/or any other action which cannot be directly ascertained, have to be properly and correctly
disposed of in accordance with national and international laws and regulations after disassembly. The same applies to
all operating materials such as oil and grease or any other materials and substances. The conscious or unconscious
reuse of used parts such as impellers, roller bearings, V-belts, etc., could pose a risk of danger to persons, harm to the
environment and damage to plant and machinery.
Collect all oil, grease and cloths/cotton waste soiled with oil and grease in suitably marked
containers and dispose of them in accordance with regulations.

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19 Spare parts
Stocks of key spare parts and wearing parts need to kept at the installation point of the system; this is a requirement for
ensuring that the fan is always in proper working order and ready for operation.
We only offer a guarantee for the genuine spare parts supplied by us.
We explicitly point out that all spare parts and accessories not supplied by us have also not been tested and approved
by us. The installation and/or use of such products can therefore, under certain circumstances, lead to negative changes
in the specified constructional characteristics of the device or system and therefore result in the compromising of active
and/or passive safety.
Karl Klein Ventilatorenbau GmbH will not accept any liability or warranty claims for damage caused by the use of non-
genuine spare parts and accessories.
Please note that special production and supply specifications often apply to in-house parts or parts from other
manufacturers and we always ensure that the spare parts we offer you are the state-of-the-art in technology and comply
with the latest statutory requirements.
When you order spare parts, it is essential that you quote the
VA number
Machine number
Part name
ID number
Item number
Order quantity
when you do so.
The machine number can be found on the rating plate on the fan.
Please address all enquiries and orders to the following address:
Karl Klein Ventilatorenbau GmbH Waldstr. 24

D-73773 Aichwald
Tel.: +49 711 36-906-0
Fax: +49 711 36-906-950 Germany
E-mail: [email protected]

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Radial Gussventilator / Radial cast fan MVG


70 Deckel / cover
180 Deckel / cover

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Radial Gussventilator / Radial cast fan TVG


70 Deckel / cover
180 Deckel / cover

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Mounting and dismounting of the fan-casing
Dismounting
1. Loosen and remove the 8 hexagon screw (M8) for the cover
2. Remove the cover
3. Remove the gasket
4. Loosen and remove the 8 hexagon screw (M8) for the motor-flange
5. Remove the fan-casing
It is not necessary to dismount the motor and impeller!
Mounting
The assembling is done in reverse order!

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20 Declaration of incorporation of partly completed machinery

Spare-part-list
High Pressure Fan
60
50
70
80
90 100 10 20 30
Legend Spare Parts List High Pressure-Fan
Position No. description

10 housing complete
20 fan wheel
30 inlet nozzle
40 suction wire mesh guard
50 motor flange
60 motor complete
70 Disc
80 Socket
90 Slice x2
100 Felt ring
1. Ordering instructions for spare parts
A clear identification and naming of the parts ensures the delivery of the correct spare part. To avoid
delivery errors and extensive description, only specify the terms and numbers listed in the parts list.
Order address:
Set up your spare parts orders:
FA. Karl Klein Ventilatorenbau GmbH

Waldstraße24
D-73773 Aichwald
Tel.: 0711 – 36906-0
Fax.: 0711 – 36906-50
Seite 1|1
Stand: 10/19
G:\TB\DOKUMENTATIONEN\Ersatzteillisten
8. Armaturen
8. Valves

Commission-N°:
7001021687
Factory-N°:
4020005 Project:
TIMOR 2
Drawing-N°:
BB2285B
Baujahr: Pos.-Nr.:
Datenblätter und Betriebsanleitungen

Datasheets and Operating Instructions
12MAM65AA005
9 12MAM65AA010 3 JASTA GD-6 3" 150# Body 1.4301 notch lever Butterfly Valve
12MAM65AA020
12MAM65AA510
11 2 RITAG ZRK3 3" 150# SS wafer type Check Valve
12MAM65AA520
12MAM60AA010 Body A105N
12 2 AVA Alms 1D00222 1" 150# hand wheel Globe Valve
12MAM60AA030 seat 13Cr
13 12MAM60AA020 1 GESTRA UNA 45 1/2" Body A105N -- float steam trap
Commission-No.:
Customer:

7001021687
Quantity/discription: Order-No.:
Factory-No.:
4020005 TIMOR 2
Project:
Drawing-No.:
67-3266 BB285B
Project-No.:
Baujahr: Pos.-Nr.:
2021 --
Pos.-No.:
Pos. 9
12MAM65AA005 /
12MAM65AA010 /
12MAM65AA020
Butterfly Valve
Type GD-6
Butterfly Valve Type GD-6 with mounted pneumatic actuator
Exploded view of a standard GD-6 with a swing through cast-iron disk and a pneumatic actuator.
GD-6
General Description of the Butterfly Valve Type GD-6
The GD-6 butterfly valve is one of our all-rounders With our three sided jacketed sealing gasket we can
in the fields of control valve technology and shut-off implement an impermeability of at least 99,95% at
valve technology. They are clamped between flanges high pressure when compared to fully opened valve
(PN-6 to PN-16) in pipelines. We can produce this disks.
valve from any materials available on the market,
depending on the application (temperature, ele- We do not only offer our valves with free end-
ment, pressure). Custom made orders and customer shafts, but can also upon requests offer the valves
requests are always possible after consultation. either as manually operated (with locking mecha-
nism or continuously variable fine adjustment) or
Special valves which have already been imple- an actuator. Any actuator available on the market
mented are a water-cooled GD-6 valve and a lever can be fitted with our DIN ISO 5211 mounting kit.
system valve that allows multiple valves to be cont- Any further adaption is possible depending on the
rolled at once. customer’s request.
Advantages at a glance
Handling Easy, depending on the accessories
Impermeability 99%, 99,8% and 99,98% compared to fully opened disk
Temperature Application -100°C to +1100°C
Element Compatibility Design and material selection according to your element and further
operating conditions, including: (aggressive) flue gas, dust laden elements,
biogas or exhaust gases from biomass burning
Reliability Very low possibility of failure
Maintenance Characteristics Low maintenance
GD-6
Basic Information
Sizes: DN 15 – DN 2000 implemented as a standard
Up to DN 5000 possible as a custom order
GD-6 as an intermediate flange design to clamp between flanges according to

DIN EN 1092-1, PN-6/PN-10/PN-16
ANSI B 16.5 – 150 lbs / 300 lbs / 400 lbs
Every clamping possibility available upon request
Centering aid guarantees an exact fitting in the pipeline
Operation
With free shaft-ends
Manual operation with a grid handle with locking mechanism or continuously variable fine adjustment
A corresponding shaft adaption with the DIN ISO 5211 mounting kit
With an attached actuator (pneumatic, electric or hydraulic)
Shaft Seal
Gland seal
O-Rings or shaft seals (EPDM, FPM, NBR, PTFE)
Smooth running seal
TA-Luft
Shaft Bearing
Friction bearing (EN-GJL-250, RG7, Rhyolite, PTFE, DU)
External fitting through flange bearings for smooth operating
External fitting over a friction bearing (EN-GJL-250CrNi-bearing blocks) for high temperatures up to 1100°C
Impermeability classes
Approx. 99% impermeability in a swing through design
Approx. 99% impermeability (metallic sealing) compared to fully opened valve disk in a design with a stop bar
in the body
Approx. 99,98% impermeability (with flexible seal) in designs with a stop bar and three sided jacketed gasket
in the body
Temperature Application
From -100°C to +1100°C
Material
Cast iron (e.g. EN-GJL-250, EN-GJL-250CrNi, 1.4848, 1.4865)
Steel (e.g. S235JR, S355JR)
Stainless steel (e.g. 1.4301, 1.4541, 1.4571, 2.4610)
Heat resistant steel (e.g. 1.4828, 1.4841)
Aluminium
Duplex
GD-6
Closing Types
Swing through 99% impermeability compared to fully opened disk
With a stop bar in the body 99,5% to 99,8% impermeability compared to fully opened disk
With stop bar and gasket seal 99,95% to 99,98% impermeability compared to fully opened disk
With sealing air Up to 100% impermeability
Material Combinations
Temperature up to 350°C from 350°C- 450°C from 450°C- 550°C from 550°C - 750°C from 750°C-
1100°C
Body EN-GJL-250; EN-GJL-250; EN-GJL-250CrNi; EN-GJL-250CrNi, 1.4828
Alu EN-GJL-250CrNi; 1.4301; 16Mo3
P265GH
Disk EN-GJL-250; EN-GJL-250; 1.4301; EN-GJL- 1.4541; 1.4828
St. 37; 1.4301 1.4301; P265GH 250CrNi; 16Mo3 EN-GJL-250CrNi
Shaft St. 37; 1.4021 1.4021; 1.4541 1.4021; 1.4305; 1.4541 1.4541 1.4828
Note: The material combinations listed here are standard combinations. The exact selection is made for special designs and
special requests in accordance with specifications or after consulting with you.
Actuators and Actuator Accessories

Operation Accessory
Manual operation Grid handle, fine adjustment, worm gear
Pneumatic actuator Magnet valve, electro-mechanical end switch, inductive proximity switch
positioner 4...20mA, PROFIBUS, HART, etc.
Elektric actuator End switch, revolution off-switch, position encoder 4…20mA, positioner,
PROFIBUS, HART
Security functions Fast closing and opening <1 sec through express airing or fall weights
Cylinder Magnet valve, End position control
Advantages of the GD-6

Our valves are individually produced according to your needs. They are adjusted one hundred percent accor-
ding to the operational conditions. That includes the specifications, material choice and operation.
The Kv-values, impermeability and dynamic torque are according to our standards and tested in an FEM si-
mulation. Here the advantages are shown between cast disks and steel disks when it concerns the imperme-
ability of the disk.
The intermediate flange design GD-6 is produced with a centering aid. This ensures easy installation and cen-
tering the valve between the flanges of the pipeline.
GD-6
6 References
References
BÜTTNER Gesellschaft für Trocknungs- und Umwelttechnik mbH, Krefeld
Loesche ThermoProzess GmbH, Gelsenkirchen
Riedhammer GmbH, Nürnberg
„ We are using to sell them to kilns and oven manufacturers that use the valves on
smokes and hot air plants. In every situation your valves have given very good
results and the customers have been always satisfied of the products.
We hope you will go on to make your valves like you are doing now.
R. Bovo / Econex, Italy
Application Areas
Smelters, foundries, cement factories, crematoriums, industrial ovens (for iron, steel, aluminium and stainless
steel), glass factories, factories (for Rockwool, porous concrete etc.), ceramic ovens, drying and dust extractors,
gas turbines, heat treatment, and high temperature oven construction.
Our delivery supply range: Sensors according to determination of the mass flows. Our flow measurement
sensors measure independently from pressure, temperature and element. Further information upon request.
GD-6
Technical Data 7
Standard Measurements GD-6 with Grid Handle

15 25 60 44 8 100 130 1
20 25 60 44 8 100 130 1,1
25 25 75 60 10 100 145 1,2
32 25 80 67 10 100 150 1,4
40 25 83 75 10 145 163 1,5
50 25 85 85 10 145 165 1,6
65 30 95 105 12 145 175 2,2
80 30 105 120 12 145 185 2,5
100 30 115 140 12 145 195 2,8
125 35 135 170 12 145 215 4,8
150 40 150 195 15 155 235 5,7
175 40 165 225 15 155 250 7,5
200 40 175 255 15 155 260 8,8
225 40 185 280 15 155 270 11,5
250 40 220 310 15 155 305 13,9
300 45 240 360 20 155 325 22,6
350 45 290 415 25 210 410 27
400 50 335 465 30 210 455 39
450 50 360 520 30 210 480 45
500 55 400 570 30 210 520 56
550 60 420 620 30 210 540 78
600 65 460 675 30 210 580 82
GD-6
8 Technical Data
Standard Measurements GD-6 with Fine Adjustment SFD-6

15 25 60 44 8 100 130 1
20 25 60 44 8 100 130 1,1
25 25 75 60 10 100 145 1,2
32 25 80 67 10 100 150 1,4
40 25 83 75 10 145 163 1,5
50 25 85 85 10 145 165 1,6
65 30 95 105 12 145 175 2,2
80 30 105 120 12 145 185 2,5
100 30 115 140 12 145 195 2,8
125 35 135 170 12 145 215 4,8
150 40 150 195 15 155 235 5,7
175 40 165 225 15 155 250 7,5
200 40 175 255 15 155 260 8,8
225 40 185 280 15 155 270 11,5
250 40 220 310 15 155 305 13,9
300 45 240 360 20 155 325 22,6
350 45 290 415 25 210 410 27
400 50 335 465 30 210 455 39
450 50 360 520 30 210 480 45
500 55 400 570 30 210 520 56
550 60 420 620 30 210 540 78
600 65 460 675 30 210 580 82
GD-6
Technical Data 9
Standard Measurements GD-6 with Fine Adjustment RDST-32

15 25 60 44 8 255 165 1
20 25 60 44 8 255 165 1,1
25 25 75 60 10 255 180 1,2
32 25 80 67 10 255 185 1,4
40 25 83 75 10 255 188 1,5
50 25 85 85 10 255 190 1,6
65 30 95 105 12 255 200 2,2
80 30 105 120 12 255 210 2,5
100 30 115 140 12 255 220 2,8
125 35 135 170 12 255 240 4,8
150 40 150 195 15 255 255 5,7
175 40 165 225 15 255 270 7,5
200 40 175 255 15 255 280 8,8
225 40 185 280 15 255 290 11,5
250 40 220 310 15 255 325 13,9
300 45 240 360 20 290 365 22,6
350 45 290 415 25 290 420 27
400 50 335 465 30 290 465 39
450 50 360 520 30 290 490 45
500 55 400 570 30 290 530 56
550 60 420 620 30 290 550 78
600 65 460 675 30 290 590 82
700 70 495 780 35 400 657 120
800 75 545 880 40 400 707 180
900 80 600 980 40 400 762 220
1000 90 670 1080 45 400 832 240
1100 90 730 1180 45 400 892 295
1200 90 790 1295 45 400 952 345
GD-6
10 Technical Data
Standard Measurements GD-6 with Free Shaft and Fitting
DN B C D d H approx. Mass [kg]

15 25 60 44 8 140 1
20 25 60 44 8 140 1,1
25 25 75 60 10 155 1,2
32 25 80 67 10 160 1,4
40 25 83 75 10 163 1,5
50 25 85 85 10 165 1,6
65 30 95 105 12 175 2,2
80 30 105 120 12 185 2,5
100 30 115 140 12 195 2,8
125 35 135 170 12 225 4,8
150 40 150 195 15 240 5,7
175 40 165 225 15 255 7,5
200 40 175 255 15 265 8,8
225 40 185 280 15 275 11,5
250 40 220 310 15 320 13,9
300 45 240 360 20 340 22,6
350 45 290 415 25 420 27
400 50 335 465 30 465 39
450 50 360 520 30 490 45
500 55 400 570 30 530 56
550 60 420 620 30 550 78
600 65 460 675 30 590 82
700 70 495 780 35 625 120
800 75 545 880 40 675 180
900 80 600 980 40 730 220
1000 90 670 1080 45 820 240
1100 90 730 1180 45 880 295
1200 90 790 1295 45 940 345
GD-6
Technical Data 11
Standard Measurements GD-6 with ISO 5211 Mounting Kit
DN B C D d E approx. Mass [kg]

15 25 60 44 8 200 ( 160 ) 2,4
20 25 60 44 8 200 ( 160 ) 2,5
25 25 75 60 10 200 ( 160 ) 2,6
32 25 80 67 10 200 ( 160 ) 2,7
40 25 83 75 10 200 ( 160 ) 2,8
50 25 85 85 10 200 ( 160 ) 2,9
65 30 95 105 12 200 ( 160 ) 3,6
80 30 105 120 12 200 ( 160 ) 3,9
100 30 115 140 12 200 ( 160 ) 4,3
125 35 135 170 12 200 ( 160 ) 6,1
150 40 150 195 15 200 ( 160 ) 7,7
175 40 165 225 15 200 ( 160 ) 9,8
200 40 175 255 15 200 ( 160 ) 11,2
225 40 185 280 15 200 ( 160 ) 12,9
250 40 220 310 15 200 ( 160 ) 16,4
300 45 240 360 20 200 ( 160 ) 23,3
350 45 290 415 25 200 ( 160 ) 31,9
400 50 335 465 30 200 ( 160 ) 44,1
450 50 360 520 30 200 ( 160 ) 47
500 55 400 570 30 200 ( 160 ) 64,6
550 60 420 620 30 200 ( 160 ) 82
600 65 460 675 30 200 ( 160 ) 84
700 70 495 780 35 200 ( 160 ) 122
800 75 545 880 40 200 ( 160 ) 184
900 80 600 980 40 200 ( 160 ) 224
1000 90 670 1080 45 200 ( 160 ) 256
1100 90 730 1180 45 200 ( 160 ) 311
1200 90 790 1295 45 200 ( 160 ) 361
GD-6
12 Technical Data
Standard Measurement GD-6 with Double External Bearing
DN B C D d K H approx. Mass [kg]

15 - - - - - - -
20 - - - - - - -
25 25 75 60 10 160 315 8,6
32 25 80 67 10 160 320 8,8
40 25 83 75 10 160 323 8,9
50 25 85 85 10 160 325 9
65 30 95 105 12 160 335 9,6
80 30 105 120 12 160 345 9,9
100 30 115 140 12 160 355 10,2
125 35 135 170 12 160 385 12,2
150 40 150 195 15 160 400 13
175 40 165 225 15 160 415 15
200 40 175 255 15 160 425 16
225 40 185 280 15 160 435 19
250 40 220 310 15 160 480 21
300 45 240 360 20 160 500 30
350 45 290 415 25 160 580 46
400 50 335 465 30 160 625 58
450 50 360 520 30 160 650 64
500 55 400 570 30 160 690 75
550 60 420 620 30 160 710 97
600 65 460 675 30 160 750 101
700 70 495 780 35 160 785 139
800 75 545 880 40 160 835 200
900 80 600 980 40 160 890 230
1000 90 670 1080 45 160 980 260
1100 90 730 1180 45 160 1040 320
1200 90 790 1295 45 160 1100 370
GD-6
Technical Data 13
Kv-values of the GD-6

5° 1 2 3 4 6 9 16 26 37
10 ° 2 3 5 8 12 18 31 49 70
15 ° 4 6 9 14 22 32 57 88 127
20 ° 6 9 14 22 35 50 89 139 201
25 ° 8 14 21 32 50 72 128 201 289
30 ° 11 18 28 44 68 98 175 273 393
35 ° 14 24 37 58 90 130 231 361 520
40 ° 19 32 48 76 118 170 302 472 680
45 ° 25 42 63 98 154 222 394 616 886
50 ° 32 54 82 129 201 290 515 804 1158
55 ° 42 71 108 169 263 379 674 1054 1518
60 ° 55 93 142 221 346 498 885 1383 1991
65 ° 73 123 186 290 453 653 1160 1813 2610
70 ° 95 160 243 380 593 854 1519 2373 3417
75 ° 123 208 315 492 769 1108 1969 3077 4431
80 ° 166 281 425 665 1039 1496 2659 4155 5984
85 ° 207 349 529 827 1292 1861 3308 5169 7443
90 ° 227 384 582 909 1420 2045 3635 5680 8179
5° 50 65 83 102 147 200 261 331 408
10 ° 96 125 158 196 282 384 501 634 783
15 ° 173 226 286 353 509 693 905 1145 1414
20 ° 273 357 452 558 803 1093 1428 1807 2231
25 ° 393 514 650 803 1156 1573 2055 2600 3210
30 ° 536 699 885 1093 1574 2142 2798 3541 4372
35 ° 708 925 1171 1446 2082 2833 3701 4684 5782
40 ° 926 1209 1530 1889 2720 3702 4835 6120 7555
45 ° 1206 1576 1994 2462 3546 4826 6303 7977 9849
50 ° 1576 2059 2606 3217 4632 6305 8235 10423 12867
55 ° 2066 2698 3414 4215 6070 8262 10791 13658 16861
60 ° 2711 3540 4481 5532 7966 10842 14161 17923 22127
65 ° 3553 4641 5874 7251 10442 14213 18564 23494 29005
70 ° 4651 6075 7688 9491 13668 18603 24298 30752 37966
75 ° 6031 7878 9970 12309 17725 24126 31511 39881 49236
80 ° 8144 10637 13463 16621 23934 32577 42549 53852 66483
85 ° 10131 13232 16746 20675 29771 40522 52927 66986 82699
90 ° 11132 14540 18402 22718 32714 44527 58158 73607 90872
Please contact us should you need the valves in larger sizes.
GD-6
14 Custom Designs
Custom Designs
According to your individual needs, we produce the GD-6 in different material combinations and for different
actuators and applications.
GD-6 GD-6 GD-6

With side mounted Reduced Brush valve
actuator diameter for flow elements
Glossary
Butterfly Valve A butterfly valve consists of a body and is for flow regulation. Clamped between flanges.
Centering Aid Lugs right and left of the operating side shaft outlet of the valve. They ensure easier and more
precise installation into a pipeline.
Closing Contact of the valve disk with the body. Possible seals: Striking, swing through, with stop bar
and stop bar with seals.
Coupling Connection between the actuator and the valve shaft.
Electric Operation Electric operation of the valve. Control over 4 .. 20 mA-signal possible. Wide ranging optional
accessories available.
Element Element flowing through the valve. (Gas, liquid, etc.)
External Seal Used at high temperatures to guarantee the turning of the valve at all operating conditions.
Fine Adjustment Lever which has a free swing variance of 90° and is movable per wing screw or clamp lever into
any position.
Fitting Key Metallic adaption of the shaft to the actuator. This is a side connected metal lug on the shaft.
Serves for power transfer from the actuator to the shaft.
Flange Bearing Serves as transmission of high torques.
Four Cornered Shaft Serves for the adaption of the shaft to the required connection of the actuator.
Grid Handle Gear teeth on a nut screwed scale provides the possibility of a gradual adjustment of the valve
disk. The catch of the hand lever locks into the teeth. 16 positions between 0 and 90 ° are fixed.
Hand Operation With grid handle, fine adjustment or worm gear. Depending on installation.
Hydraulic Operation Operates with a hydraulic cylinder. Special: Good power distribution in limited spaces.
Impermeability Shows how impermeable the flow is inside the valve. (Dependant on construction, classified in
leakage rates).
GD-6
Glossary 15
Inner Sizing Internal flow area of the valve.
Installation Position Describes the horizontal or vertical position of the shafts of the valve once installed.
ISO 5211 Norm regulates the attachment measurements for actuators to attachment parts onto valves.
Kv 90° Flow in a fully open valve disk.
Lever System It regulates two or more valves with an actuator.
Mounting Kit Normed part for mounting actuators.
Nominal Size Size of the inner measurement of the valve.
Operation Operation of the valve. Possible operation: manual, pneumatic- und electric actuators
(as standard). All further adaptions available as per customer needs.
Operational Pressure Pressure in the pipeline which works on the valve.
Operational Temperature Temperature of the element in the pipeline.
Packing Gasket Serves as the seal between the valve and shaft exit from the valve body. Can be produced in
various ways. (EPDM, PTFE, TA-Luft eg.)
Pneumatic Operation Opening of the disk in the valve with a pneumatic actuator. With or without a spring setting.
Control possible with a positioner.
RDST-32 Infinitely adjustable fine adjustment for larger valves.

Safety Position This is decided by the customer. Defines the position of the valve in an emergency.
Seal Flexible material in the valve. To improve the impermeability.
Sealing Air Used to seal the shaft up to 100%.
Service Defines the regular necessary readjustments (readjustment of the packaging, etc.).
For the maintenance plan please see operating and maintenance manual.
SFD-6 Infinitely adjustable fine adjustment with a manual handle, used in smaller valves.
Shaft Bearing Bears of the shafts in the body.
Slide Bearing Turned sleeve, e.g. from red brass.
Step-seated Disk valve fitted in the body of the valve and stops the flow.
Stop bar Metallic valve stop in the valve. Serves to seal the valve.
Swing-through Valve without seals between the disk and body with defined ring gap.
TA-Luft German Clean Air Act (§48 BImSchG). Using a TA-Luft packing ensures 100% seal of the shaft
bushing to the outside.
GD-6
16
Certificates
We are certified for the following processes:
ISO 9001
AD 2000 HP0
EN 3834-2
SIL
ATEX
Services for the Valves

We are happy to support you with various services
to optimize the use of the valve.
Determination of sound level

Expertise on earthquake safety
Strength calculation
FEM calculation Test station at JASTA-ARMATUREN
Leakage calculation
Flow simulations
Assembly and test run of your actuator
Lacquering to your liking
JASTA-ARMATUREN GmbH & Co. KG
Levinstr. 156-160
45356 Essen
Germany
Phone: +49 - (0)201 - 86602-0

Fax: +49 - (0)201 - 86602-21
www.jasta-armaturen.com
[email protected]
GD-6
Pos. 11
12MAM65AA510 /
Valve Experience. 12MAM65AA520
Made in Germany.
Einsatzgrenzen (Pressure / Temperature Ratings)
TMA (°C) -200 -10 100 200 300 400

class 150 PMA (bar) 16 16 14 11 10 9
Leckrate G (met., PTEE) bzw. Leckrate A (NBR, EPDM, FKM) nach EN 12266-1
Leakage G (met., PTEE) resp. leakage A (NBR, EPDM, FKM) acc. to EN 12266-1
Werkstoffe (Materials)
Gehäuse / Body Platte / Disc

Stainless Steel / Edelstahl Stainless Steel / Edelstahl DN 2“ - 20“
class 150
Elastische Dichtung möglich – Einsatzgrenzen siehe Technische Informationen: Dichtungen Verwendung

Elastic seat rings available – operating limitations see Technical Information: Seat Rings
• Flüssigkeiten
• Dämpfe
• Gase
• Fluidgruppe 1 gemäß
DGRL 2014 / 68 / EU
Öffnungsdrücke (Opening Pressures)
Application
• Fluids
DN PÖ (mbar) • Steam
• Gas
• Fluidgroup 1 acc. to
2“ ~0 8 PED 2014 / 68 / EU
2 ½“ ~0 8
Bei Einsatz in Prozessanlagen
3“ ~0 8
verwenden Sie bitte unsere
4“ ~0 8 Type ZRD.
5“ ~0 8 For applications in process plants
6“ ~0 8 please select our type ZRD.
8“ ~0 12
10“ ~0 12
12“ ~0 12
14“ ~0 15
16“ ~0 16
18“ ~0 16
20“ ~0 22
= Durchflussrichtung / Flow direction

Technische Änderungen vorbehalten 08/2017
Armaturenwerk KG Fax +49 (0) 47 95-5 50 42-850 1
Valve Experience.
Made in Germany.
Maße und Gewichte (Dimensions and Weights)
Maße / dimensions in mm
DN L D A d0 d1 kg
(cl. 150)
2“ 20 101 42 26 62 1,3
2 ½“ 20 120 55 38 78 1,6
3“ 20 133 60 42 95 1,9
4“ 20 171 80 70 118 2,3
5“ 21 193 100 92 140 3,4
6“ 22 219 120 114 172 4,5
8“ 29 274 155 143 228 8,5
10“ 34 336 200 185 271 13,0
12“ 38 406 232 214 296 20,0
Baulänge in Anlehnung an API 6D
14“ 44 447 271 263 360 26,0 Face / Face dimension acc. to API 6D
16“ 51 511 310 305 405 36,0
18“ 60 546 360 342 440 61,0 Passend zwischen Flansche ASME B16.5RF
For fitting between flanges acc. to ASME B16.5RF
20“ 64 603 400 400 500 85,0
Druckverlustdiagramm (Pressure Drop Chart)
Die Diagrammwerte gelten für Wasser bei 20°C. Sie resultieren aus
Messungen an Ventilen beim Einbau in horizontaler Leitung. Beim Einbau
in vertikaler Leitung ergeben sich im Teilöffnungsbereich unbedeutende
Abweichungen. Um Druckverrluste bei anderen Medien zu ermitteln, ist
zuvor der äquivalente Wasservolumenstrom nach folgender Formel zu
berechnen:
Graph readings apply to water at 68° F (20° C). They result from
measurements on valves installed in horizontal pipes.
For installation in vertical pipes insignificant devitations occur
in the partial opening. In order to determine pressure losses for
other media the equivalent water flow has to be calculated before
applying the following formula:
. . ρ
VW = V
1000
.
VW [m3/h] äquivalenter Wasservolumenstrom
equivalent water flow
[kg/m3] Dichte des Mediums (Betriebszustand)
. density of medium at working conditions
V [m3/h] Volumenstrom des Mediums (Betriebszustand)
flow of medium at working conditions Technische Änderungen vorbehalten 08/2017
Armaturenwerk KG Fax +49 (0) 47 95-5 50 42-850
Pos. 12
12MAM60AA010 /
12MAM60AA030
Technische Änderungen vorbehalten/Subject to technical alterations
1)
ASME-Faltenbalgventil Class 150, verschweißter Deckel, Regulierkegel B.F.E. FIG. 1JHWL 300
1)
ASME Bellows Sealed Globe Valve Class 150, welded bonnet, plug type disc B.F.E. FIG. 1JHWL 300
D
12
13 Werkstoffe/Materials:
11 1 Gehäuse/Body 1.0460 ~ A105N
10 2 Oberteil/Bonnet 1.0460 ~ A105N

8
3 Kegel/Disc 13Cr
9 4 Sitzring/Seat ring 13Cr stellitiert/stellited
H (geöffnet/open)
2 7 5 Spindel/Stem 13Cr
6 Faltenbalg/Bellows 1.4571 ~ A182-F316Ti
nach TA-Luft/VDI 2440
acc. TA-Luft/VDI 2440 7 Stopfbuchspackung/Gland packing Graphit(e)
5 (low emission execution)
Stopfbuchsbrille/Gland flange
8 A105N ~ 1.0460
9 Stopfbuchshülse/Gland follower 13Cr
6
10 Stopfbuchsschrauben/Gland bolts A2-70
11 Stopfbuchsmuttern/Gland nuts A2-70
12 Spindelmutter/Stem nut 13Cr
B 4)
13 Handrad/Handwheel Stahl/Steel
4
1
3)
L
Maße/Dimensions:
Nennweite/Size 1/2" 3/4" 1" 1.1/2" 2"
L 3) 108 117,5 127 166,5 203
H (geöffnet/open) 170 175 205 260 300
D 88 88 97 138 172
B 4) 89 98,5 108 127 152,5
Gewicht ca./Weight approx. kg 3,0 3,8 5,5 10,3 17,6
2)
Drehmoment/Torque Nm * * * * *
AVA-Artikel-Nr./-Item-No. 1N00220 1N00221 1N00222 1N00223 1N00224
Baulängen , Anschlüsse: Face to face dimensions , Connections:

3) 3)
Baulängen nach ASME B16.10 Face to face dimensions acc. ASME B 16.10
4) 4)
Flanschmaße nach ASME B 16.5 Flanges acc. ASME B 16.5
Dichtleiste RF/SF (Ra = 3,2 - 6,3 µm) Flange face finish RF/SF (Ra = 3,2 - 6,3 µm)
Bemerkungen: Remarks:
1) 1)
Armatur nach BS 5352, DGRL 2014/68/EU, AD 2000 A4, Valve acc. BS 5352, PED 2014/68/EU, AD 2000 A4, TA-Luft 2002/VDI 2440,
TA-Luft 2002/VDI 2440, NACE sauergasbeständig, ATEX 2014/34/EU NACE sour gas resistant, ATEX 2014/34/EU
2) 2)
Die angegebenen Drehmomente sind max. Drehmomente The shown torques are max. torques for clean water at ambient temperature
für Medium Wasser bei Raumtemperatur
* *
Auf Anfrage On request
Rev.-Nr./Rev.No.: Datum/Date: Best.-Nr./Order No.: Ident.-Nr./Tag No.:
5/RB 02.02.2017
ARMATUREN VERTRIEB HOLTERKAMP 1 TEL.: +49 2102/4390-0 [email protected]

ALMS GMBH D-40880 RATINGEN FAX: +49 2102/4390-99 WWW.AVA-ALMS.DE
Pos. 13
Data Sheet 819345-03
12MAM60AA020 Issue Date: 03/17

UNA 45, UNA 46, UNA 46A
PN 40/Class 300
DN 15, 20, 25, 40, 50, 65
Description The different equipment versions allow you to adjust the flow
direction of the equipment to the flow pattern of your installa-
Float traps type UNA 45 are designed for removing conden-
tion. The flow arrow must correspond to the direction of the
sate from steam or compressed air.
fluid flow. The following positions of installation are possible:
Float traps type UNA 46 and UNA 46A are designed for remo-
ving condensate from steam or other gases / gas mixtures.
UNA 45 hl, UNA 46 hl, UNA 46A hl
Equipment fitted with control unit SIMPLEX and SIMPLEX-P
is operated and controlled by the float and the rolling ball.
Equipment with this type of control unit is particularly suitable v
for cold condensate and cold distillates. v
v
The rolling ball of the control unit SIMPLEX-P is made of
Perbunan® rubber, which ensures tight shut-off of the seat.
Equipment with control unit DUPLEX may also be used for “v” for installation in vertical pipework with downward flow
air venting the installation. This type of control unit is parti-
cularly suitable for saturated steam systems. The control unit
DUPLEX consists of a float operated rolling ball valve and a
temperature dependent air-venting facility. Do not expose the hl
membrane regulator capsule of the DUPLEX control unit to hl
UNA 45 hl Sightglass cover hl
superheat conditions above 5 K.
By means of the externally adjustable internal bypass it is
possible to adjust a bypass passage that flows past the
control unit. “hl” for horizontal left
The equipment must only be used within the allowable pres-
sure and temperature limits and only if the chemical and
corrosive influences on the equipment are taken into account. hr
hr
hr
Function
The control unit opens the orifice as a function of the liquid
level. A rising level results in a proportional opening of the
equipment. The max. discharge capacity depends on the “hr” for horizontal right
orifice size when the ball is completely lifted off its seat and
the orifice is fully open.
Materials
UNA 45 hl Cover for mounting electrodes Optional extras Component
Type EN ASTM
part
Vent hole and drain hole
Float-lifting lever allows the float to be manually lifted UNA 45,
1.0460 A105
(for purging any dirt away from the seat area) Body UNA 46
Hand-vent valve allows manual air-venting the pipeline UNA 46A 1.4404 A182-F316L
Strainer
UNA 45
Horizontal flow direction (hr) from left to right sightglass
(when viewed from the body end) cover /
5.3103 A3951)
Control unit SIMPLEX-P with Perbunan® rolling ball cover for
Externally adjustable inner bypass Cover installing
electrodes
Sightglass cover PN 16/CL 150
Special cover for installing measuring electrodes UNA 46 1.0619 A216-WCB
NRG 16-19 or NRG 16-27
UNA 46A 1.4408 A351-CF8M
End connections Body gasket,

control all Graphite CrNi
Flange EN 1092-1 B1 PN 40 unit gasket
Flange ASME B 16.5 Class 150 RF, 300 RF
Other
Screwed sockets G: ISO 228/1 all Stainless steel
components
Screwed sockets NPT: ASME B 16.11
1) Physical and chemical properties comply with EN grade.
Socket-weld ends to DIN EN 12760
ASTM nearest equivalent grade is stated for guidance only.
Socket-weld ends ASME B 16.11 Class 3000
Butt-weld ends via transition pieces to EN 12627, welded
joint geometry ISO 9692-1 code number 1.3 (30° chamfer)
Butt-weld ends via transition pieces ASME B 16.25
ASME B 36.10
1
Components UNA 45, UNA 46, UNA 46A Item no. Designation
2 3 27 4 2 Body
13 3 Body gasket
4 Control unit SIMPLEX
13 Hand-vent valve
16 Float-lifting lever
18 Control unit DUPLEX
Control unit SIMPLEX-P with Perbunan®
19
rolling ball
Control unit DUPLEX with externally
20
adjustable internal bypass
27 Gasket
28 Control membrane
Socket spanner 16
28 18 19 20
H2
X H2
H H
L
L
H1
H1
X
B B
UNA 45, UNA 46, UNA 46A L1 UNA 45, UNA 46, UNA 46A
Control unit DUPLEX Control unit DUPLEX
with flanged ends with screwed connections
X
Externally adjustable
internal bypass
To remove the cover a withdrawal space S of 240/350 mm

(depending on size) is required.
If the supplied socket spanner is attached to the equipment
an additional clearance of 100 mm is required.
S
2

DN 15 DN 20 DN 25 DN 40 DN 50 DN 65
Nominal size
(½") (¾") (1") (1½") (2") (2½")
B [mm (in)]
Standard cover 171 (6.7) 287 (11.3)
H1 [mm (in)] 60 (2.4) 107 (4.2)
H2 [mm (in)] 90 (3.5) 1) 151 (5.9) 1)
Width L1 [mm (in)] 110 (4.3) 2) 170 (6.7) 2)
X [mm (in)] 13 (0.5)
Weight [kg]
Standard cover 6.8 7.3 7.8 24.8 26.2 28.6
Weight [lb]
Standard cover 15.0 16.1 17.2 54.7 57.8 63.1

DN 15 DN 20 DN 25 DN 40 DN 50 DN 65
Nominal size
(½") (¾") (1") (1½") (2") (2½")
Overall length L [mm (in)] 150 (5.9) 160 (6.3) 241 (9.5) 267 (10.5) 292 (11.5)
B [mm (in)]
Standard cover 171 (6.7) 287 (11.3)
H1 [mm (in)] 60 (2.4) 107 (4.2)
H2 [mm (in)] 90 (3.5) 1) 151 (5.9) 1)
Width L1 [mm (in)] 110 (4.3) 2) 170 (6.7) 2)
X [mm (in)] 13 (0.5)
Weight Class 150
Weight [kg]
Standard cover 6.2 6.6 7.2 23.8 25.9 29.4
Weight [lb]
Standard cover 13.7 14.6 15.9 52.5 57.1 64.8
Weight Class 300
Weight [kg]
Standard cover 6.6 7.4 8.2 26.0 27.5 31.1
Weight [lb]
Standard cover 14.6 16.3 18.1 57.3 60.6 68.6
3
Dimensions and weights – continued –

DN 15 DN 20 DN 25 DN 40 DN 50 DN 65
Nominal size
(½") (¾") (1") (1½") (2") (2½")
95 (3.7) 165 (6.5) 267 (10.5) 292 (11.5)
Overall length L [mm (in)]
(Socket-weld end) (Butt-weld end via transition pieces EN, ASME)
B [mm (in)]
Standard cover 171 (6.7) 287 (11.3)
H1 [mm (in)] 60 (2.4) 107 (4.2)
H2 [mm (in)] 90 (3.5) 1) 151 (5.9) 1)
Width L1 [mm (in)] 110 (4.3) 2) 170 (6.7) 2)
X [mm (in)] 13 (0.5)
Weight [kg]
Standard cover 5.3 5.2 21.2 21.9 24.6
Weight [lb]
Standard cover 11.7 11.5 46.7 48.3 54.5

DN 15 DN 20 DN 25 DN 40 DN 50
Nominal size
(½") (¾") (1") (1½") (2")
B [mm (in)]
Standard cover 171 (6.7) 287 (11.3)
H1 [mm (in)] 60 (2.4) 107 (4.2)
H2 [mm (in)] 90 (3.5) 1) 151 (5.9) 1)
Width L1 [mm (in)] 110 (4.3) 2) 170 (6.7) 2)
X [mm (in)] 13 (0.5)
Weight [kg]
Standard cover 5.3 5.2 5.1 21.2 20.9
Weight [lb]
Standard cover 11.7 11.5 11.2 46.7 46.1

DN 15 DN 20 DN 25 DN 40 DN 50 DN 65
Nominal size
(½") (¾") (1") (1½") (2") (2½")
B [mm (in)]
Standard cover 171 (6.7) 287 (11.3)
H1 [mm (in)] 60 (2.4) 107 (4.2)
H2 [mm (in)] 90 (3.5) 1) 151 (5.9) 1)
Width L1 [mm (in)] 110 (4.3) 2) 170 (6.7) 2)
X [mm (in)] 13 (0.5)
Weight [kg]
Standard cover 5.6 5.7 21.3 21.6 22.5
Weight [lb]
Standard cover 12.3 12.6 47.0 47.6 49.6
4
Pressure & temperature ratings Operating data
The values indicated in the following tables apply to standard equipment. Equipment with sightglass cover:
Note that the type of end connection used may restrict the use of the equipment to below the pressure/temperature limits PN 16: max. service temperature 240 °C at
quoted. 12.3 bar service pressure
All equipment specific values are indicated on the nameplate. Class 150: max. service temperature 240 °C at
12.4 bar service pressure. If the pH value
is above 9.0 and the fluid temperature
Limiting conditions for UNA 45 and UNA 46: Flange PN 40, screwed sockets G, exceeds 200 °C the glass will wear down
butt-weld ends EN faster.
Equipment with measuring electrode
Pressure1) p [barg] 40 37.1 33.3 27.6 25.7 13.12)
NRG 16-19 or NRG 16-27,
Temperature1) T [°C] –10/20 100 200 300 350 4502) PN 40/Class 300: max. service temperature 238 °C at
with Perbunan rolling ball:
ΔPMX [psi] 29, 58, 116, 188, 320, 465 max. service temperature 40 °C at ΔPMX
16 bar.
to the saturated steam temperature +5 K.
Pressure1) p [psig] 580 538 483 400 373 1902)
Temperature1) T [°F] 14/68 212 392 572 662 8422)
2) Not for UNA 45
Pressure1) p [barg] 19.6 17.7 13.8 10.2 8.6 5.52)
Temperature1) T [°C] –29/20 100 200 300 345 4252)
Max. admissible differential pressure [bar] 2, 4, 8, 13 (19,6 bar with orifice (AO) 22, 32)
Pressure1) p [psig] 285 260 200 140 125 802)

Temperature1) T [°F] – 20/100 200 400 600 650 8002)
2) Not for UNA 45

Flange Class 300, screwed socket NPT, socket-weld end, butt-weld end ASME
Pressure1) p [barg] 51.1 46.6 43.8 39.8 37.8 28.82)
Temperature1) T [°C] –29/20 100 200 300 345 4252)

ΔPMX [psi] 29, 58, 116, 188, 320, 465
Pressure1) p [psig] 740 280 635 570 550 4102)

Temperature1) T [°F] – 20/100 200 400 600 650 8002)
2) Not for UNA 45
Limiting conditions for UNA 45 with sightglass cover: flange PN 16, screwed sockets G,
butt-weld ends EN
Pressure1) p [barg] 16.0 14.8 14.0 13.3 12.3
Temperature1) T [°C] –10/20 100 150 200 240
ΔPMX [psi] 29, 58, 116, 188, (230 psi with orifice (AO) 22, 32)
Pressure1) p [psig] 232 215 203 193 178

Temperature1) T [°F] 14/68 212 302 392 464
5
Pressure & temperature ratings – continued – Operating data
Limiting conditions for UNA 45 with sightglass cover: PN 16: max. service temperature 240 °C at
flange Class 150, screwed sockets NPT, socket-weld end, butt-weld end ASME
Pressure1) p [barg] 19.6 17.7 15.8 13.8 12.4 12.4 bar service pressure. If the pH value
Temperature1) T [°C] –29/20 100 150 200 240 is above 9.0 and the fluid temperature
exceeds 200 °C the glass will wear down
faster.
Max. admissible differential pressure [bar] 2, 4, 8, 13, (19,6 bar with orifice (AO) 22, 32) Equipment with measuring electrode
ΔPMX [psi] 29, 58, 116, 188, (284 psi with orifice (AO) 22, 32) NRG 16-19 or NRG 16-27,
Admissible service temperature Control unit DUPLEX: Saturated steam temperature plus 5 K PN 40/Class 300: max. service temperature 238 °C at
Pressure1) p [psig] 285 260 230 200 180 with Perbunan rolling ball:
Temperature1) T [°F] –20/100 200 300 400 465 max. service temperature 40 °C at ΔPMX
1) Resistance limits of body/cover to ASME B 16.5 16 bar.
Limiting conditions for UNA 46A: flange PN 40, screwed sockets G, butt-weld ends EN to the saturated steam temperature +5 K.
Pressure1) p [barg] 40.0 37.9 31.8 27.6 25.7 25
Temperature1) T [°C] –10/20 100 200 300 4002) 4502)

ΔPMX [psi] 29, 58, 116, 188, 320, 465
Pressure1) p [psig] 580 550 461 400 373 363

Temperature1) T [°F] 14/68 212 392 572 752 842
Limiting conditions for UNA 46A: flange Class 150

Pressure1) p [barg] 15.9 13.3 11.2 10.0 6.5 5.5
Temperature1) T [°C] –29/20 100 200 300 4002) 4252)
Max. admissible differential pressure [bar] 2, 4, 8, 13, (15,9 bar with orifice (AO) 22, 32)
Pressure1) p [psig] 230 195 160 140 95 80

Temperature1) T [°F] – 20/100 200 400 600 750 800
Limiting conditions for UNA 46A:

flange Class 300, screwed socket NPT, socket-weld end, butt-weld end ASME
Pressure1) p [barg] 41.4 34.8 29.2 26.1 24.3 23.9
Temperature1) T [°C] –29/20 100 200 300 4002) 4252)

ΔPMX [psi] 29, 58, 116, 188, 320, 465
Pressure1) p [psig] 600 510 420 370 355 345

Temperature1) T [°F] –20/100 200 400 600 750 800
6
Capacity Chart Capacity Chart
The chart shows the maximum capacities for hot condensate
for the various orifices. [lb/h] [kg/h]
The capacities are dependent on the differential pressure 15000 7000
(working pressure). 6000
2
The differential pressure is the difference between inlet and 5000 AO
10000 65-
outlet pressure and depends among other things on the 40-
4000 DN O4 AO
8
run of the condensate line. If the condensate downstream 8000 -A - 22
0-6
5
-65 13 - AO 32
of the trap is lifted, the differential pressure is reduced by 4 0 O AO
3000 DN N4 -A -65 -
approximately 1 bar for 7 m lift. 6000 D -65 40 -65
40 DN 40
The max. admissible differential pressure is a function of DN DN
the cross-sectional area of the orifice and the density of the 2000
4000
fluid to be discharged.
The graphs in the chart show the hot water flowrates that the 3000 4
steam traps UNA 45, UNA 46 and UNA 46A can discharge - AO
with virtually no banking up. 1000 2 -25 O
8
3
2000 AO 15 -A O1
The cold water capacities of steam traps with control unit - DN 5-2
5 -A 22
800 5 -25 N1 5-2
5
AO
SIMPLEX / DUPLEX are: Capacity multiplied by factor F. 1 -
DN
D
D N1 -25 O3
2
600 15 -A
DN 5-2
5
1
1000
500 DN
400
800
300
600
Durchfluss
200
Capacity
400
300
100
200 [bar]
0,1 0,2 0,3 0,4 0,6 0,8 1 2 3 4 5 6 8 10 20 32
[psi]
1,5 2 3 4 6 8 10 20 30 40 60 80 100 200 300 465
Differenzdruck
Differential pressure
Factor F = 1 1.1 1.18 1.2 1.3 1.4 1.48 1.53
The max. differential pressure Δ PMX of the equipment depends on the type of orifice (AO) used.
Diameter of bore [mm]
Orifice ΔPMX [bar]
DN 15-25 DN 40-65
2 2 8 15.0
4 4 6 12.5
8 8 4.8 10.0
13 13 4.1 8.5
22 22 3.5 7.0
32 32 3.0 6.5
7
Ball Float Steam Trap Spare Parts
3 27 4
UNA 45, UNA 46, UNA 46A 13 31
PN 40/Class 300
DN 15, 20, 25, 40, 50, 65 12
Inspection & Certification

Documentation regarding material tests and in-house
examination with test report to EN 10204 available at extra
cost. All inspection requirements have to be stated with the
enquiry or order. After supply of the equipment certification
cannot be established. Charges and extent of the above 1 Delivery quantity: 20 pcs.
mentioned test certificates as well as the different tests 16 32 2 560486: Material 1.4301
confirmed therein are listed in our Price List “Test and In-
560514: Material 1.4571
spection Charges for Standard Equipment”. For other tests 28 18 19 20 3 Comprises:
and inspections please consult us.
4 joint rings 3/8"
1 joint ring ¼"
Application of European Directives 1 body gasket
Pressure Equipment Directive 1 gasket for control unit
The equipment conforms to this directive and can be used
DN 15-25 DN 40-65
for the following media:
Cover for Cover for
UNA 45 Standard Sightglass Standard Sightglass
Item no. Designation Orifice mounting mounting
Fluids of group 2 cover cover cover cover
electrodes electrodes
UNA 46 and UNA 46A Stock code #
Fluids of group 1
Fluids of group 2 2 560656 560669
ATEX Directive Control unit 4 560657 560670
SIMPLEX, cpl. with 8 560658 560671
The equipment does not have its own potential ignition source
3, 4, 27 body gasket and
and is not subject to this directive. 13 560659 560672
gasket for control
When installed, static electricity may arise between the unit 22 560660 – 560673 –
equipment and the connected system. When used in po-
tentially explosive atmospheres, the plant manufacturer or 32 560661 – 560674 –
plant operator is responsible for discharging or preventing Control unit
possible static charge. SIMPLEX-P, cpl.
If it is possible for medium to escape, e.g. through actuating 3, 19, 27 with body gasket 16 560662 –
mechanisms or leaks in threaded joints, the plant manufacturer and gasket for
or plant operator must take this into consideration when control unit
dividing the area into zones. 2 560650 560663
Control unit 4 560651 560664
DUPLEX, cpl. with 8 560652 560665
3, 18,
body gasket and
27, 28 13 560653 560666
gasket for control
unit 22 560654 – 560667 –
32 560655 – 560668 –
Membrane regulator
3, 28 capsule 5N2, cpl. with all 560494 560687
body gasket
Hand vent valve,
12, 13 complete with all 560676 – 560676 560676 – 560676
gasket
Float-lifting lever,
12, 16 complete with all 560677 560678
gasket
3 Body gasket1) all 560493 560680
Joint ring for sealing

plug 3/8",
12 manual float-lifting all 5604862) or 5605142)
lever, hand-vent
valve or bypass1)
27 Gasket for control unit1) all 560681 560682

3, 12, 27 Gasket set3) all 560683 – 560684 –
Sightglass, incl.
Supply in accordance with our general terms of business. 31, 32 all – 560685 – 560480
gasket
GESTRA AG
Münchener Straße 77, 28215 Bremen, Germany
Telefon +49 421 3503-0, Telefax +49 421 3503-393
E-mail [email protected], Web www.gestra.de
819345-03/03-2017cm (808923-02) · GESTRA AG · Bremen · Printed in Germany
8
UNA 45
UNA 46
UNA 46A
Original Installation Instructions

819311-02
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 ......................................................................................................................................5
Typographic features of warning notes ....................................................................................................5
Formatting features for warnings of property damage ..............................................................................5
Description .........................................................................................................................................6
Scope of supply and equipment specification ..........................................................................................6
Task and function ..................................................................................................................................9
Storing and transporting the equipment.........................................................................................10
Storing the equipment .........................................................................................................................10
Transporting the equipment .................................................................................................................11
Mounting and connecting the equipment .......................................................................................11
Preparing installation ...........................................................................................................................11
Orientation of the equipment ................................................................................................................12
Connecting the equipment ...................................................................................................................13
Operation ..........................................................................................................................................16
After operation .................................................................................................................................17
Removing external dirt deposits ............................................................................................................18
Maintaining the equipment ...................................................................................................................18
Servicing the equipment and installing spare parts ................................................................................22
Troubleshooting ...............................................................................................................................30
Putting the equipment out of operation ..........................................................................................32
Removing harmful substances ..............................................................................................................32
Removing the equipment .....................................................................................................................32
Re-using equipment after storage .........................................................................................................33
Disposing of the equipment ..................................................................................................................34
Technical data ..................................................................................................................................35
Dimensions and weights ......................................................................................................................35
Pressure & temperature ratings ............................................................................................................42
Manufacturer's declaration .............................................................................................................47
Foreword Cross-reference
This installation & operating manual will help you  Listing
use the following types of equipment safely and  Sub-items in listings
efficiently for their intended purpose.
 Steps for action.
 UNA 45
 UNA 46 Here you will find additional useful
 UNA 46A information and tips serving to assist you
in using the equipment to its fullest
These steam traps will be called equipment in this potential.
document.
This installation & operating manual is intended for

anyone commissioning, using, operating, servicing, Safety
cleaning or disposing of this equipment and, in
particular, for professional after-sales service Use for the intended purpose
technicians, qualified personnel and authorised and
The following ball float steam traps are designed to
trained staff.
discharge condensate from steam systems:
All of these persons must read and understand the
 UNA 45
content of this installation & operating manual.
 UNA 46
Following the instructions given in this installation &
operating manual helps avoiding danger and  UNA 46A
increases the reliability and service life of the
Equipment type UNA 45 can also be used for
equipment. Please note that in addition to the
instructions given in this installation & operating
systems.
manual you must also observe all locally applicable
rules and regulations concerning the prevention of Equipment type UNA 46 and UNA 46A can also be
accidents as well as approved safety guidelines for used for removing condensate from gases or gas
good professional practice. mixtures.
The equipment must only be used within the

Availability allowable pressure and temperature limits and only
if the chemical and corrosive influences on the
Keep this installation & operating manual together equipment are taken into account.
with the plant documentation for future reference.
Make sure that this installation & operating manual Do not expose the membrane regulator capsule of
is available to the operator. the DUPLEX control unit to superheat conditions
The installation & operating manual is part of the above 5 K.
equipment. Please hand over this installation & Correct use includes compliance with the
operating manual when selling the equipment or instructions given in this installation & operating
passing it on. manual, in particular obedience to all safety
instructions.
Formatting features in the Any other use of the equipment is considered to be

improper.
document
Note that the equipment is also used incorrectly if
Certain text elements of this installation & operating
the materials of the equipment are not suitable for
manual feature a specific typographic design. You
the fluid.
can easily distinguish the following text elements:
Standard text
3
Basic safety notes temperature ratings see name plate and the
section "Technical Data".
Risk of severe injuries
Risk of minor injuries
 The equipment is under pressure during
operation and may be hot. Before carrying out  Sharp edges on internals present the danger of
any work on the equipment make sure that the cuts to hands. Always wear industrial gloves
following requirements are met: when servicing the equipment.
 The pipes must be depressurized (0 bar).  If the support of the equipment during
installation is insufficient the equipment might
 The fluid must be completely removed from fall down, thereby causing bruises or injuries.
the pipes and the equipment. Make sure the equipment is safely held in place
 During work on the equipment the during installation and cannot fall down. Wear
installation must be switched off and protective safety footwear.
protected against unauthorised or
unintended activation.
Information on property damage
 The pipes and the equipment must have
cooled down to room temperature (approx.
or malfunctions
20 °C).  Malfunctions will occur if the equipment is
 If the equipment is used in contaminated areas installed in a wrong position or with the flow
there is a risk of severe injuries or death caused arrow pointing in the opposite direction of the
by harmful substances in or on the equipment. fluid flow. This may result in damage to the
Before working on the equipment make sure equipment or the installation. Make sure that
that it is completely decontaminated. Always the flow arrow on the equipment body matches
wear the protective clothing prescribed for the indicated direction of the fluid flow in the
contaminated areas when working on the pipe.
equipment.  If the material is unsuitable for the fluid,
 The equipment must only be used with fluids increased wear may occur and fluid may
that do not attack the material and the gaskets escape. Make sure that the material is suitable
and sealings of the equipment. Otherwise leaks for the fluid used in your installation.
may occur and hot or toxic fluid could escape.
 The equipment and its component parts must Qualification of personnel
only be mounted or removed by qualified A qualified person must be acquainted with and
personnel. A qualified person must be experienced in the following:
acquainted with and experienced in the  the pertinent on-site rules and regulations for
following: preventing fire and explosions as well as
 Making pipe connections. industrial safety regulations
 Selecting suitable lifting gear and  working on pressure equipment
understanding the rules for its safe use.  making pipe connections
 Working with dangerous (contaminated, hot  working with dangerous (hot or pressurized)
or pressurized) fluids. fluids
 If the admissible temperature and pressure  lifting and transporting loads
limits are exceeded the equipment may be
destroyed and hot or pressurized fluid may  observing all notes and instructions in this
escape. Make sure that the equipment is only installation & operating manual and the
operated within the admissible service range applicable documents
and limits.
For more information on limits and pressure &
4
Protective gear Typographic features of warning
The operator must ensure that anyone working on notes
the equipment must wear the required protective
clothing and safety gear stipulated for the site of
installation. The protective clothing must be suitable
DANGER
for the used media and must protect the wearer Notes with the heading DANGER warn
against safety and health hazards associated with a against imminent dangerous situations that
particular job to be carried out at the site of can lead to death or serious injuries.
installation. Protective clothing & equipment must
provide protection from potential hazards, in
particular from injuries to:
WARNING
 Head
 Eyes Notes with the heading WARNING warn
against possibly dangerous situations that
 Body could lead to death or serious injuries.
 Hand
 Feet
 Hearing CAUTION
Note that this list is not exhaustive. The operator Notes with the heading CAUTION warn
must establish personal protective equipment against dangerous situations that could
guidelines and specify any additional protective lead to minor or moderate injuries.
gear that is required if the worker is exposed to a
specific risk at the site of installation.
Formatting features for warnings
of property damage
Attention!
This information warns of a situation
leading to property damage.
5
Description
Scope of supply and equipment

specification
Scope of supply
Our equipment is delivered packed and ready for
assembly.
Equipment specification

no. no.
1 Direction of flow arrow 6 Name plate
2 Body 7 Cover (shown here: standard cover)
3 Body gasket 8 Orifice
4 Control unit (shown here: control unit 9 Screws (4 pcs.)
SIMPLEX)
5 Float
6
Optional extras
The following items are available as optional extra:

no. no.
10 Strainer 14 Sightglass cover with integrated reflexion
11 Sealing plug water level indicator
12 Gasket 15 Drain with sealing plug
13 Hand-vent valve with socket spanner 16 Float-lifting lever with socket spanner
(socket spanner not shown) 17 Cover with connections for electrodes
The vent hole in the cover for the hand- NRG 16-19 or NRG 16-27
vent valve can also be used for
connecting a balance line.
7
The equipment can be fitted optionally with the The different equipment versions allow you to adjust
following control units: the flow direction of the equipment to the flow
pattern of your installation. The flow arrow must
correspond to the direction of the fluid flow. The
following positions of installation are possible:
 "v" for installation in vertical pipework with
downward flow
 "hl" for flow from right to left (when viewed from
the body end)
 "hr" for flow from left to right (when viewed from
the body end)
Item Designation
no.
18 Control unit DUPLEX with membrane
regulator capsule
19 Control unit SIMPLEX-P with Perbunan®
rolling ball
20 Control unit with externally adjustable
internal bypass
End connections
The equipment is available with the following end
connections:
 Flanges
 Screwed sockets
 Socket-weld ends
 Butt-weld ends via transition pieces
8
Name plate Application of European Directives
The following items are indicated on the name
Pressure Equipment Directive
plate:
The equipment conforms to this directive (see
 Manufacturer
"Manufacturer's Declaration" section) and can be
 Type designation used for the following media:
 Design UNA 45
 Nominal size  Fluids of group 2
 Pressure rating
UNA 46 and UNA 46A
 Design temperature
 Design pressure
 Max. service temperature
 Max. admissible differential pressure ATEX Directive
 CE marking The equipment does not have its own potential
 Date of manufacturing ignition source and is not subject to this directive
 Material number (see "Manufacturer's Declaration" section).
The following items are indicated on the equipment When installed, static electricity may arise between
body: the equipment and the connected system.
 Material When used in potentially explosive atmospheres,
 Batch code the plant manufacturer or plant operator is
responsible for discharging or preventing possible
 Direction of flow static charge.
The following items are indicated on the end
connections: If it is possible for medium to escape, e.g. through
actuating mechanisms or leaks in threaded joints,
 Flange size
the plant manufacturer or plant operator must take
 Flange face type (RJ number) this into consideration when dividing the area into
 Thread type zones.
The limiting conditions and pressure &

temperature ratings specified in this Task and function
installation manual are applicable for
standard equipment. Note that these Purpose
values may differ for modified or UNA 45, UNA 46 and UNA 46A is steam process
customized equipment. equipment designed for the effective removal of
All equipment specific values are indicated condensate from steam.
on the nameplate. Equipment type UNA 45 can also be used for
systems.
Equipment type UNA 46 and UNA 46A can also be
used for removing condensate from gases or gas
mixtures.
9
Function Storing and transporting the
A ball float opens the orifice as a function of the equipment
liquid level, thereby controlling the condensate
flowrate to be discharged. The max. discharge
capacity depends on the orifice size when the ball is Attention!
completely lifted off its seat and the orifice is fully
open. Equipment can be damaged if stored or
transported improperly.
Equipment with a control unit type SIMPLEX is
particularly suitable for cold condensates and  Close all openings with the sealing
superheated steam. plugs or covers supplied with the
Equipment fitted with control unit SIMPLEX-P is equipment or use similar sealing
operated and controlled by the float and the rolling covers.
ball. The Perbunan® rubber rolling ball ensures tight  Protect the equipment against
shut-off at the seat. Equipment with this type of moisture and corrosive atmospheres.
control unit is particularly suitable for cold
condensate and cold distillates.  Please contact the manufacturer if the
specified transport and/or storage
Equipment with control unit DUPLEX may also be
requirements cannot be met.
used for air venting the installation. The control unit
DUPLEX consists of a float operated rolling ball
valve mechanism and, in addition, a temperature
dependent air-venting facility. The air venting is
Storing the equipment
controlled by the membrane regulator. Equipment  Please observe the following items when storing
with this type of control unit is particularly suitable the equipment:
for saturated steam systems. Do not expose the
 Do not store the equipment for more than 12
membrane regulator capsule of the DUPLEX control
months.
unit to superheat conditions above 5 K.
 Use the supplied sealing plugs or other suitable
The optional float-lifting lever allows you to lift the
seal caps in order to seal off all openings of the
float manually.
equipment.
The optional hand-vent valve allows you to air vent
 Protect the sealing surfaces and contact areas
the pipe manually.
against mechanical damage.
By means of the externally adjustable internal
 Protect the equipment and all components
bypass it is possible to adjust a bypass passage
against hard shocks and impacts.
that flows past the control unit.
 Store the equipment only in closed rooms that
meet the following environmental conditions:
 Air humidity below 50 %, not condensing
 Indoor air: clean, salt-free and non-corrosive
 Temperature 5–40 °C.
 Make sure that all these requirements are

always met when storing the equipment.
 Please contact the manufacturer if you cannot
comply with the recommended storage
conditions.
10
Transporting the equipment Mounting and connecting the
equipment
CAUTION
Do not drop the equipment. If it falls down
Preparing installation
it may cause bruises and injuries.  Take the equipment out of the transport
packaging.
 To transport and mount the equipment
safely use suitable lifting gear.  Check the equipment for transport damage.
 Contact the manufacturer if you detect any kind
 Connect the noose strap of the lifting of shipping damage.
gear to the body.
When supplied by the factory, the connections may
 Provide sufficient support for the
be sealed off with sealing plugs.
equipment during transport and
installation.  Remove sealing plugs before mounting the
equipment.
 Wear protective safety footwear.
 Keep the sealing plugs and the packing for
Lightweight equipment may be transported and further use.
mounted without using any lifting gear.
To lift equipment the weight of which exceeds
approx. 25 kg, you need the help of a second
person or suitable lifting gear.
Your physical strength and on-site regulations and
conditions determine what weight can be lifted and
 Meet the requirements for storage also when
transporting the equipment.
 Prior to transport seal off connections with
sealing plugs.
If you do not have the sealing plugs
supplied with the equipment use
appropriate seal caps to seal off the
connections.
 For short distances (only a few metres) you can
transport the equipment unpacked.
 When transporting the equipment over larger
distances use the original packaging.
 If you do not have the original packaging use a
box that protects the equipment adequately
against corrosion and physical damage.
For a short period of time the equipment
may be transported even if the
temperature is below 0 °C, provided that
the equipment is completely empty and
dry.
11
Orientation of the equipment
DANGER The different equipment versions allow you to adjust
Personnel working on pipes are exposed to the flow direction of the equipment to the flow
safety risks and may suffer severe injuries, pattern of your installation. The following positions
poisoning or even loss of life. of installation are possible:
 with horizontal connections "hl" and "hr" for
 Make sure that no hot or hazardous installation in horizontal pipes
 with vertical connections "v" for installation in
 Make sure that the pipes upstream vertical pipework with downward flow
and downstream of the equipment are
depressurised.
 Make sure that the installation is
Attention!
switched off and protected against Malfunctions may occur if the control unit
unauthorised or unintended activation. is installed incorrectly.
 Make sure that the equipment and the  When installing the equipment make
pipes have cooled down to room sure that the name plate on the cover
temperatures. is on top and the float arm is free to
 Wear protective clothing that is move up and down.
To avoid malfunctions make sure the following
requirements are met when mounting the
For more information on suitable protective clothing equipment:
and safety gear refer to the safety data sheet of the  The flow arrow on the equipment body must
fluid in question. match the fluid flow direction.
 The name plate on the cover must point
 Drain pipes until they are empty.
upwards.
 Switch the installation off and protect it against
unauthorised or unintended re-activation.  Contact the manufacturer if you want to mount
the equipment in a different position of
installation.
page 19.
page 19.
 Turn the control unit by 90° or 180° into the
desired position of installation.
 Make sure that the float arm is free to move up
and down.
page 20.
page 21.
12
Connecting the equipment
Attention!
DANGER Equipment will be damaged if the end
connections are undersized.
Incorrectly connected equipment can
cause fatal accidents or severe injuries.  Make sure that the connections are
strong and rigid enough to support the
 Make sure that only qualified skilled weight of the equipment and to
personnel connect the equipment to withstand the forces that occur during
pipes. operation.
 Make sure that the flow arrow on the
equipment body matches the direction Consider space required for servicing the
of flow in the pipe. equipment and/or exchanging components and
observe the necessary withdrawal distance to
Specialist personnel must be highly qualified and remove the cover. For more information on the
fully experienced in making pipe connections for the required withdrawal distances see section
respective type of end connection. "Dimensions and weights" on page 35.
 Make sure that the pipe system of the plant is

CAUTION clean.
 Make sure that the equipment is free from
Do not drop the equipment. If it falls down foreign matter.
it may cause bruises and injuries.  Mount the equipment in the desired installation
 To transport and mount the equipment position.
safely use suitable lifting gear.  Make sure that the pipes meet the following
requirements:
 Connect the noose strap of the lifting
gear to the body.  The layout of the pipelines must prevent the
 Provide sufficient support for the formation of water pockets.
equipment during transport and  The pipeline must have a gradient so that the
installation. condensate is free to fall towards the equipment
 Wear protective safety footwear.  The cross section of the air balance pipe must
be at least DN 8 (¼ ") .
Lightweight equipment may be transported and  If the equipment is fitted with control unit
mounted without using any lifting gear. SIMPLEX, an air balance pipe must be
To lift equipment the weight of which exceeds connected to the vent hole for the hand-vent
approx. 25 kg, you need the help of a second valve. The air balance pipe must have the
person or suitable lifting gear. following end connection dimensions:
Your physical strength and on-site regulations and  Standard cover and sightglass cover: G⅜ "
conditions determine what weight can be lifted and  Cover with electrode connections: G¼ "
 If one or more of the above mentioned
requirements cannot be met, please contact our
Technical Service or authorized agency in your
country.
 Connect the end connections of the equipment
properly to the pipes.
13
 If necessary, connect the air balance pipe to the
equipment as shown in the following drawing.
 Make sure that the equipment is safely mounted

and that all connections are made correctly.
14
Mounting the measuring electrode If you want to mount a measuring electrode NRG
If the equipment has a cover with electrode 16-27 with adapter (21) in the connection on top
connections you can attach one or two measuring proceed as follows:
electrodes of the following type:  Put the adapter gasket onto the adapter.
 To detect banking-up of condensate: NRG 16-  Screw the adapter (21) with gasket into the
19 or NRG 16-27 installed on top of the body connection on top.
(22)
 Tighten the adapter to a torque of 75 Nm.
 To detect loss of water seal: NRG16–19 or
The following steps are the same for both types of
NRG16–27 installed at the side of the body (24)
installation and connections:
To attach the NRG 16-27 on top of the  Use a suitable combination spanner to screw
body of equipment with DN 15 - 25 you the measuring electrode into the desired
need an adapter (21) with gasket. You can connection (22 or 24) on the body.
order this adapter with gasket (stock code
 Tighten the measuring electrode with a torque
# 556841) from the manufacturer.
of 75 Nm.
If the equipment is fitted with a standard cover you  Connect the body to the pipework as described
can fit the measuring electrode laterally. in the previous section.
The following tool is required for installation work:  Attach an air balance pipe to the connection
G¼ ” (23).
 Combination spanner A. F. 22, 24, 27 and 32
to DIN 3113 form B
 Torque spanner (US: wrench) 60-120 Nm to
DIN ISO 6789
Attention!
The measuring electrode might get
damaged if it is mounted incorrectly.
 Do not insulate the equipment after
installation of the measuring
electrode.
 Observe and follow all instructions
given in the installation & operating
manual for the measuring electrode.
To mount the measuring electrodes proceed as

follows:
the terminal box side of the measuring
electrode.
OKS®217.
15
Before mounting measuring electrodes The cast arrow on the body indicates the correct
please note: direction of rotation.
If a measuring electrode type NRG 16–27  To open the orifice turn the socket spanner from
is mounted on top of the body, only a the tip of the arrow towards the end of the
screwed union for a pipe with cross arrow.
section 8 mm will fit into the bore G¼”. If a  To close the orifice turn the socket spanner
screwed union for a pipe with cross from the end of the arrow towards the tip of the
section 10 mm were used, the hexagon arrow.
connection would press onto the
measuring electrode. Use the socket spanner (25) supplied with the
equipment to adjust the bypass flowrate of the
optional bypass.
Operation  To reduce the quantity turn the socket spanner

clockwise.
During operation you can undertake the following
work:  To increase the quantity turn the socket spanner
anticlockwise.
 Open and close the optional hand-vent valve
 Open and close the optional manual float-lifting
lever
 Adjust the optional bypass
To do this, use the socket spanner (stock code #

526110) supplied with the equipment.
The optional hand vent valve allows manual air

venting.
 To air vent the equipment turn the hand-vent

valve (viewed from top) anticlockwise.
 To close the hand-vent valve after air-venting
turn it clockwise.
 Fasten the hand-vent valve hand tight.
You can check the correct functioning of the
The optional float-lifting lever allows the float to be equipment during operation using the GESTRA
manually lifted irrespective of the liquid level. It can ultrasonic measuring unit VAPOPHONE® or
be used to purge any dirt away from the seat area TRAPTEST® (VKP 40 and VKP 40plus).
and out of the equipment by opening the orifice and
draining the liquid.  For more details refer to the installation &
operating manual of the ultrasonic measuring
unit.
16
After operation
DANGER
DANGER If the equipment is used in contaminated
If fluid escapes personnel may suffer death caused by harmful substances in or
severe injuries, poisoning or even loss of on the equipment.
life.
 After working on the equipment make perform work on contaminated
sure that all connections and valves equipment.
are tight.
 Always wear the protective clothing
 Make sure that the gaskets of the prescribed for contaminated areas
body are leakproof. when working on the equipment.
 Make sure that the equipment is
DANGER completely decontaminated before
carrying out any service work.
Personnel working on pipes are exposed to
 Follow the pertinent instructions for
safety risks and may suffer severe injuries,
handling the hazardous substances in
question.
 Make sure that no hot or hazardous
 Make sure that the pipes upstream
Attention!
and downstream of the equipment are Frost damage may occur when the
depressurised. installation is shut down.
 Make sure that the installation is  Drain the equipment if ambient
switched off and protected against temperatures below 0 °C (frost) are to
unauthorised or unintended activation. be expected.
 Make sure that the equipment and the
pipes have cooled down to room
temperatures.
 Wear protective clothing that is

and safety gear refer to the safety data sheet of the
fluid in question.
17
 Provide a device that collects any fluid that may Maintaining the equipment
escape.
For work on the equipment you will need the
 Remove the sealing plug (15) at the bottom of following tools:
the body.
 Combination spanner form B to DIN 3113, sizes
 Allow all liquid to escape and wait until the body
is completely empty.  A. F. 17 mm
 To seal the drain hole screw in the sealing plug  A. F. 22 mm
and tighten it with a torque of 75 Nm.  A. F. 24 mm
 A. F. 32 mm
 Torque spanner to DIN ISO 6789
 up to 10 Nm
 10 – 60 Nm
 60 – 120 Nm
 120 – 300 Nm
 Allen key to DIN ISO 2936, sizes
 A. F. 4 mm
 A. F. 6 mm
 A. F. 8 mm
 Screwdriver 5.5/125 to DIN 5265
Malfunctions may occur if the equipment is

used with different types of condensate:
Removing external dirt deposits
The following condensates in particular
 To remove dirt deposits rinse the equipment cause problems:
 very oily condensates
free cloth.
 condensates that resinify or become
gummy
and carefully wipe the equipment with a clean,  condensates that recrystallize
lint-free cloth.  condensates that contain solid matter.
In these cases check the equipment at
regular intervals for contamination and, if
necessary, remove dirt deposits.
To reduce contamination we recommend
installing a sedimentation vessel or a dirt
pocket arrangement upstream of the
equipment.
Normally you do not have to clean the internal parts

of the equipment.
To clean the equipment completely take off the
cover and remove the control unit.
The following drawings show equipment

type UNA 4 with standard cover.
18
Removing cover Removing control unit
Remove the measuring electrode(s) if  Detach the cover from the body as described on
mounted, before lifting off the cover. page 19.
 Use a combination spanner A. F. 32 to  Remove the socket-head cap screws (26).
DIN 3113, form B, to remove the  Detach the control unit (4) from the body (2).
measuring electrode.  Remove the gasket (27) for the control unit.
 Remove the four screws (9) in the body.  For the disposal of the gaskets observe the
 Lift the cover (7) off the body (2). pertinent on-site regulations concerning waste
disposal.
 Remove the body gasket (3).
 For the disposal of the body gasket observe the
pertinent on-site regulations concerning waste
disposal.
Cleaning the equipment

Check the equipment at regular intervals for
contamination. The intervals depend on the amount
of dirt in the system. The operator must determine
the maintenance intervals.
 Remove any parts that are dirty and cannot be

cleaned properly.
To clean the inside of the equipment proceed as

follows:

page 19.
page 19.
 To remove dirt deposits rinse the equipment
free cloth.
and carefully wipe the equipment with a clean,
lint-free cloth.
19
 Fix the control unit to the body as described on Fitting control unit in place
page 20.
 Attach the cover to the body as described on Attention!
page 21.
Malfunctions may occur if the control unit
Cleaning and checking the membrane is installed incorrectly.
regulator capsule  When installing the equipment make
To clean the membrane regulator capsule of sure that the name plate points
equipment with a DUPLEX control unit proceed as upwards and the float arm is free to
follows: move up and down.
 Detach the cover from the body as described on  Make sure that the flow arrow on the
page 19. equipment body matches the direction
 Remove the control unit as described on of flow in the pipe.
page 19.
 Check all removed parts for signs of damage.
 Remove the membrane regulator capsule as
described in section "Exchanging the membrane  Replace all worn or damaged parts.
regulator capsule" on page 28.  Clean all dirty parts.
 Clean the membrane regulator capsule with cold  Apply high-resistant lubricant to all threads,
clean water. bearing faces of screws, nuts and bolts.
 Use a depth gauge to check the dimension x of The lubricant must have the same properties as
the membrane regulator capsule as shown in OKS® 217.
the following drawing.
Attention!
damaged.
 Replace all gaskets that you loosen
The membrane regulator capsule is intact if during your work.
dimension x exceeds 4.0 mm.
 Use only new gaskets of the same
 Discard and replace defective membrane type.
regulator capsule with a new one.
 Mount the membrane regulator capsule as
described in section "Exchanging the membrane
regulator capsule" on page 28.
20
 Replace all gaskets with new ones of the same Mounting cover
type.
 Insert a new gasket (27) for the control unit into Attention!
the body (2).
 Turn the control unit (4) into the desired position Equipment may leak if the gasket is
of installation. damaged.
 Make sure that the control unit is not tilted or  It is therefore essential that you
skewed when fitted into the body. always insert a new gasket before re-
 Fix the control unit in place using the socket- attaching the cover.
head cap screws (26).  Make sure that the cover is not tilted
or skewed when refitted.
The tightening torque of the socket-head cap
screws depends on the equipment type.
 Clean the gasket surfaces of the cover and
 Equipment with DN 15 up to DN 25 requires a body.
torque of 4 Nm.
 Equipment with DN 40 up to DN 65 requires a bearing faces of the screws.
torque of 7 Nm.
 Fasten the socket-head cap screws with the OKS® 217.
specified tightening torque.
 Put a new body gasket (3) onto the body (2).
 Insert the four screws (9) into the bores of the
body.
 Refit the cover (7) onto the body such that the
name plate (6) points upwards.

page 21.
21
The tightening torque of the screws depends on the
equipment type.
torque of 35 Nm.
torque of 140 Nm.
 Tighten the four screws with the specified

torque.
 If necessary, mount the measuring electrode as
described on page 15.
Servicing the equipment and installing spare parts

You may exchange the following component parts
in case of wear or damage:
UNA 45, UNA 46 and UNA 46A with standard cover
22
Spare parts for equipment with standard cover
Stock code #
8 560658 560671
13 560659 560672
22 560660 560673
32 560661 560674
8 560652 560665
13 560653 560666
22 560654 560667
32 560655 560668
with body gasket
3 Body gasket 1
all 560493 560680
2
float-lifting lever, hand-vent valve or

externally adjustable inner bypass1
all 560683 560684

3 Comprises:
 1 body gasket
23
UNA 45 with cover for installing electrodes
24
Spare parts for UNA 45 with cover for installing electrodes
Stock code #
3.4, 27 Control unit SIMPLEX, cpl. with body 2 560656 560669
8 560658 560671
13 560659 560672
22 560660 560673
32 560661 560674
8 560652 560665
13 560653 560666
22 560654 560667
32 560655 560668
with body gasket
3 Body gasket1 all 560493 560680
12 Joint ring for sealing plug ⅜” or manual all 560486 or 5605142
2
float-lifting lever1
all 560683 560684

3 Comprises:
 1 body gasket
25
UNA 45 with sightglass cover
26
Spare parts for UNA 45 with sightglass cover
Stock code #
8 560658 560671
13 560659 560672
8 560652 560665
13 560653 560666
with body gasket
3 Body gasket 1
all 560493 560680
2
float-lifting lever or hand-vent valve1

31, 32 Reflexion water level gauge with 2 gaskets all 560685 560480

27
Exchanging the control unit
page 19.
page 19.
page 20.
page 21.
Exchanging the membrane regulator capsule

page 19.
In equipment with DN 15–DN 25 the cover

presses the membrane regulator capsule
onto the seat. You can therefore easily
detach the membrane regulator capsule
from the seat after removing the cover. Install the new membrane regulator capsule as
follows:
In equipment with DN 40 and DN 50 a
mounting clip is used to fix the membrane  Press the membrane regulator capsule onto the
regulator capsule in place. To exchange seat until it snaps into place.
the membrane regulator capsule first you  Slip the mounting clip over the membrane
have to remove the mounting clip. For this regulator capsule.
purpose you have to remove the control  Attach the cover to the body as described on
unit. Proceed as follows: page 21.
 Push the mounting clip (29) off the control unit
 Pull the membrane regulator capsule (28)
upwards and off the seat (2.).
28
Replacing the sightglass of the sightglass
cover Attention!
 Remove the socket-head cap screws (34).
 Detach the flange (33) from the sightglass cover damaged.
(14).
 Remove the outer gasket (32).  Replace all gaskets that you loosen
during your work.
 Remove the sightglass (31).
 Remove the inner gasket (32).  Use only new gaskets of the same
type.
 For the disposal of the gaskets observe the
pertinent on-site regulations concerning waste  Apply heat resistant lubricant to the threads and
disposal. bearing faces of the socket-head cap screws.
OKS® 217.
 Insert a new gasket in the sightglass cover.
 Insert a new sightglass.
 Put a new gasket on the sightglass.
 Screw the socket-head cap screws into the
bores of the flange.
 Tighten the socket-head cap screws alternately
and in several steps with a torque of 12 Nm.
29
Troubleshooting
The equipment is cold or only The inlet or outlet shut-off valves Fully open the shut-off valves.
warm to the touch. are closed.
Insufficient flowrate.
the user.
The equipment is cold or only The inlet, outlet or internals are If fitted, operate the float-lifting lever.
warm to the touch. dirty. Clean the pipes.
Insufficient flowrate. Clean the equipment.
the user.
Insufficient flowrate. The equipment is undersized. Install equipment with larger flowrate
Insufficient thermal output of capacity.
the user.
Insufficient flowrate. The differential pressure is too Increase the steam pressure.
Insufficient thermal output of small. Lower the pressure in the condensate
the user. lines.
Install equipment with larger flowrate
capacity.
Insufficient flowrate. The line leading to the equipment Lay the condensate line with a gradient
Insufficient thermal output of does not have a gradient. so that the condensate is free to fall
the user. towards the equipment.
Change the orientation of the pipeline.
Insufficient flowrate. Insufficient deaeration. Connect an additional air vent in
Insufficient thermal output of accordance with the instructions given by
the user. the manufacturer.
Contact the manufacturer to find out
which trap type is the most suitable for
your application.
Insufficient flowrate You did not remove the sealing Remove the equipment.
plugs from the connections. Remove the sealing plugs.
Mount the equipment.
The equipment is blowing off Dirt deposits, sediments or If fitted, operate the float-lifting lever.
live steam. foreign particles have Clean the equipment.
accumulated in the equipment.
If necessary, replace internal parts or the
whole equipment.
30
The equipment is blowing off The control unit is damaged or Replace the control unit.
live steam. worn. Replace the equipment with a new one.
The equipment is blowing off The bypass is open. Close the bypass.
live steam.
Fluid escapes (equipment is The connections are not tight. Provide the connections with leakproof
leaking). seals.
Fluid escapes (equipment is A gasket is damaged. Check the condition of the gaskets.
leaking). Replace any defective gasket.
Fluid escapes (equipment is The body has been damaged by Check the resistance of the material for
leaking). corrosion or erosion. the fluid used.
Use only equipment made of material
that is suitable for the fluid used.
Fluid escapes (equipment is The equipment is damaged. Check the condition of the equipment.
leaking). Replace the equipment if it is damaged.
leaking). damaged by frost. When shutting down the installation
make sure that all lines and the
equipment are completely drained.
leaking). damaged by waterhammer. Take appropriate measures to protect the
equipment against waterhammer, e. g.
by installing suitable non-return valves.
The stuffing box is leaking. The stuffing box packing has not Tighten the stuffing-box packing hand
been tightened enough. tight. Make sure that the stuffing box
does not impair the movement of the
internals. The stuffing box must not leak.
The stuffing-box packing is Replace the stuffing-box packing.
damaged.
 If faults occur that are not listed above or cannot
be corrected, please contact our Technical
Service or authorized agency in your country.
31
Putting the equipment out of  Remove all residues from the equipment.
operation  For the disposal of all residues observe the
pertinent legal regulations concerning waste
disposal.
Removing harmful substances
Removing the equipment
DANGER
If the equipment is used in contaminated DANGER
death caused by harmful substances in or Personnel working on pipes are exposed to
on the equipment. safety risks and may suffer severe injuries,
perform work on contaminated  Make sure that no hot or hazardous
equipment. fluid is in the equipment or the pipes.
 Always wear the protective clothing  Make sure that the pipes upstream
prescribed for contaminated areas and downstream of the equipment are
when working on the equipment. depressurised.
 Make sure that the equipment is  Make sure that the installation is
completely decontaminated before switched off and protected against
carrying out any service work. unauthorised or unintended activation.
 Follow the pertinent instructions for  Make sure that the equipment and the
handling the hazardous substances in pipes have cooled down to room
question. temperatures.
Qualified personnel must have extensive experience  Wear protective clothing that is
with and a working knowledge of: suitable for the fluid and, if necessary,
 pertinent rules and regulations concerning wear protective gear.
handling hazardous substances
 special regulations for handling the hazardous and safety gear refer to the safety data sheet of the
substances encountered on site fluid in question.
 using the required personal protective
equipment (PPE) and clothing
CAUTION
Caution Risk of injuries if the equipment falls down.
Environmental damage may be caused by  When removing the equipment make
poisonous fluid residues. sure the it is safely held in place and
cannot fall down.
make sure that it is clean and free of Suitable measures are for instance:
fluid residues.
 Equipment that is not too heavy may be
 For the disposal of all materials supported by a second person.
observe the pertinent legal regulations  For heavy equipment use suitable lifting
concerning waste disposal. equipment of sufficient strength.
32
 Detach the end connections of the equipment
from the pipes.
 Put the equipment onto a suitable base.
 Store the equipment as described in section
"Storing the equipment" from page 10
onwards.
Re-using equipment after storage

Observe the following instructions if you want to
remove the equipment and use it again somewhere
else:
 Make sure that the equipment is free of any
fluid residues.
 Make sure that all connections are in good
condition and leak-free.
 If necessary re-work welded connections in
order to ensure that they are in good working
condition.
 Use the equipment only for its intended purpose

and the service conditions for which it was
specified.
33
Disposing of the equipment
Caution
Environmental damage may be caused by
poisonous fluid residues.
make sure that it is clean and free of
fluid residues.
 For the disposal of all materials
observe the pertinent legal regulations
concerning waste disposal.
The equipment is made from the following

materials:
Component part Type EN ASTM

Body UNA 45, UNA 46 1.0460 A105
UNA 46A 1.4404 A182-F316L
Cover UNA 45 sightglass 5.3103 A3951
cover / cover for
installing electrodes
UNA 46 1.0619 SA216-WCB
UNA 46A 1.4408 A351-CF8M
Body gasket, control all Graphite CrNi
unit gasket
Other components all Stainless steel
1 Physical and chemical properties comply with EN grade. ASTM nearest equivalent grade is
stated for guidance only.
34
Technical data

The drawing shows equipment with standard cover
and flanged connection for vertical downward flow.
35
(½”) (¾”) (1”) (1½”) (2”) (2½”)
(in)]
B [mm (in)]
Standard cover 171 (6.7) 287 (11.3)
electrodes
H1 [mm (in)] 60 (2.4) 107 (4.2)
H2 [mm (in)] 90 (3.5) 1
151 (5.9)1
258 (10.2)1
Width L1 [mm (in)] 110 (4.3)2 170 (6.7)2
X [mm (in)] 13 (0.5)
Weight [kg]
Standard cover 6.8 7.3 7.8 24.8 26.2 28.6
electrodes
Weight [lb]
Standard cover 15.0 16.1 17.2 54.7 57.8 63.1
electrodes

36
(½”) (¾”) (1”) (1½”) (2”) (2½”)
Overall length L [mm 150 (5.9) 160 (6.3) 241 (9.5) 267 (10.5) 292 (11.5)
(in)]
B [mm (in)]
Standard cover 171 (6.7) 287 (11.3)
electrodes
H1 [mm (in)] 60 (2.4) 107 (4.2)
H2 [mm (in)] 90 (3.5) 1
151 (5.9)1
258 (10.2)1
Width L1 [mm (in)] 110 (4.3)2 170 (6.7)2
X [mm (in)] 13 (0.5)
Weight Class 150
Weight [kg]
Standard cover 6.2 6.6 7.2 23.8 25.9 29.4
electrodes
Weight [lb]
Standard cover 13.7 14.6 15.9 52.5 57.1 64.8
electrodes
Weight Class 300
Weight [kg]
Standard cover 6.6 7.4 8.2 26.0 27.5 31.1
electrodes
Weight [lb]
Standard cover 14.6 16.3 18.1 57.3 60.6 68.6
electrodes

37
(½”) (¾”) (1”) (1½”) (2”) (2½”)
(in)] (Socket-weld end) (Butt-weld end via
transition pieces EN,
ASME)
B [mm (in)]
Standard cover 171 (6.7) 287 (11.3)
electrodes
H1 [mm (in)] 60 (2.4) 107 (4.2)
H2 [mm (in)] 90 (3.5) 1
151 (5.9)1
258 (10.2)1
Width L1 [mm (in)] 110 (4.3)2 170 (6.7)2
X [mm (in)] 13 (0.5)
Weight [kg]
Standard cover 5.3 5.2 21.2 21.9 24.6
electrodes
Weight [lb]
Standard cover 11.7 11.5 46.7 48.3 54.5
electrodes

38
Nominal size DN 15 DN 20 DN 25 DN 40 DN 50
(½”) (¾”) (1”) (1½”) (2”)
B [mm (in)]
Standard cover 171 (6.7) 287 (11.3)
electrodes
H1 [mm (in)] 60 (2.4) 107 (4.2)
H2 [mm (in)] 90 (3.5) 1
151 (5.9)1
Total height H [mm (in)] 150 (5.9)1 258 (10.2)1
Width L1 [mm (in)] 110 (4.3) 2
170 (6.7)2
X [mm (in)] 13 (0.5)
Weight [kg]
Standard cover 5.3 5.2 5.1 21.2 20.9
electrodes
Weight [lb]
Standard cover 11.7 11.5 11.2 46.7 46.1
electrodes

39
(½”) (¾”) (1”) (1½”) (2”) (2½”)
(in)]
B [mm (in)]
Standard cover 171 (6.7) 287 (11.3)
electrodes
H1 [mm (in)] 60 (2.4) 107 (4.2)
H2 [mm (in)] 90 (3.5) 1
151 (5.9)1
258 (10.2)1
Width L1 [mm (in)] 110 (4.3)2 170 (6.7)2
X [mm (in)] 13 (0.5)
Weight [kg]
Standard cover 5.6 5.7 21.3 21.6 22.5
electrodes
Weight [lb]
Standard cover 12.3 12.6 47.0 47.6 49.6
electrodes

40
To remove the cover a withdrawal space S of

240 mm is required.
If the supplied socket spanner is attached to the
equipment an additional clearance of 100 mm is
required.
41
Pressure & temperature ratings
The values indicated in the following tables apply to
standard equipment.
Note that the type of end connection used may
restrict the use of the equipment to below the
pressure/temperature limits quoted.
All equipment specific values are indicated on the
nameplate.
Limiting conditions for UNA 45 and UNA 46: Flange PN 40, screwed sockets G
Pressure1 p [barg] 40 37.1 33.3 27.6 25.7 13.12
Temperature1 T [°C] –10/20 100 200 300 350 4502

∆PMX [psi] 29, 58, 116, 188, 320, 465
Pressure1 p [psig] 580 538 483 400 373 1902

Temperature T 1
[°F] 14/68 212 392 572 662 8422

2 Not for UNA 45
Pressure1 p [barg] 19.6 17.7 13.8 10.2 8.6 5.52
Temperature T 1
[°C] -29/20 100 200 300 345 4252
Max. admissible differential pressure [bar] 2, 4, 8, 13 (19.6 bar with orifice (AO) 22, 32)
∆PMX [psi] 29, 58, 116, 188 (284 psi with orifice (AO) 22, 32)
Pressure1 p [psig] 285 260 200 140 125 802

Temperature1 T [°F] -20/100 200 400 600 650 8002

2 Not for UNA 45
42
Flange Class 300, screwed sockets NPT, socket-weld end, butt-weld end
Pressure1 p [barg] 51.1 46.6 43.8 39.8 37.8 28.82
Temperature T 1
[°C] -29/20 100 200 300 345 4252

∆PMX [psi] 29, 58, 116, 188, 320, 465
Pressure1 p [psig] 740 680 635 570 550 4102

Temperature1 T [°F] -20/100 200 400 600 650 8002

2 Not for UNA 45
Limiting conditions for UNA 45 with sightglass cover, flange PN 16, screwed sockets G
Pressure1 p [barg] 16.0 14.8 14.0 13.3 12.3
Temperature1 T [°C] -10/20 100 150 200 240
Pressure1 p [psig] 232 215 203 193 178

Temperature1 T [°F] 14/68 212 302 392 464
43
Limiting conditions for UNA 45 with sightglass cover,
flange Class 150, screwed sockets NPT, socket-weld end, butt-weld end
Pressure1 p [barg] 19.6 17.7 15.8 13.8 12.4
Temperature T 1
[°C] -29/20 100 150 200 240
Max. admissible differential pressure [bar] 2, 4, 8, 13, (19.6 bar with orifice (AO) 22, 32)
Pressure1 p [psig] 285 260 230 200 180

Temperature1 T [°F] -20/100 200 300 400 465
Limiting conditions for UNA 46A, flange PN 40, screwed sockets G

Pressure1 p [barg] 40.0 37.9 31.8 27.6 25.7 25
Temperature T 1
[°C] -10/20 100 200 300 400 450

pressure ∆PMX [psi] 29, 58, 116, 188, 320, 465
temperature
Pressure1 p [psig] 580 550 461 400 373 363

Temperature1 T [°F] 14/68 212 392 572 752 842
44
Limiting conditions for UNA 46A, flange Class 150
Pressure1 p [barg] 15.9 13.3 11.2 10.0 6.5 5.5
Temperature1 T [°C] -29/20 100 200 300 400 425
Max. admissible differential [bar] 2, 4, 8, 13, (15.9 bar with orifice (AO) 22, 32)
pressure ∆PMX [psi] 29, 58, 116, 188 (230 psi with orifice (AO) 22, 32)
temperature
Pressure1 p [psig] 230 195 160 140 95 80

Temperature1 T [°F] -20/100 200 400 600 750 800
Limiting conditions for UNA 46A,

flange Class 300,, screwed socket NPT, socket-weld end, butt-weld end
Pressure1 p [barg] 41.4 34.8 29.2 26.1 24.3 23.9
Temperature T 1
[°C] -29/20 100 200 300 400 425

pressure ∆PMX [psi] 29, 58, 116, 188, 320, 465
temperature
Pressure1 p [psig] 600 510 420 370 355 345

Temperature1 T [°F] -20/100 200 400 600 750 800
45
Operating data
PN16: max. service temperature 240 °C at
12.4 bar service pressure. If the pH value is above
9.0 and the fluid temperature exceeds 200 °C the
glass will wear down faster.
Equipment with measuring electrode NRG 16–19 or
NRG 16–27, PN40/Class300:
max. service temperature 238 °C at 32 bar service
pressure
Equipment with control unit SIMPLEX-P with
Perbunan rolling ball: max. service temperature
40 °C at ∆PMX 16 bar.
Equipment with control unit DUPLEX: The

max.service temperature corresponds to the
saturated steam temperature +5 K.
According to the Body of Regulations AD 2000
300 °C is the limit temperature for resistance to
intercrystalline corrosion occurring in UNA 46A
made from material 1.4408.

Orifice ΔPMX Diameter of bore [mm]

[bar] DN 15–25 DN 40-65
2 2 8 15.0
4 4 6 12.5
8 8 4.8 10.0
13 13 4.1 8.5
22 22 3.5 7.0
32 32 3.0 6.5
46
Manufacturer's declaration
For more information on the Conformity
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
28215 Bremen
Germany
Telefon +49 421 3503-0
Telefax +49 421 3503-393
Web www.gestra.de
This declaration is no longer valid if modifications

are made to the equipment without consultation
with us.
47
Agencies all over the world: www.gestra.de
GESTRA AG
28215 Bremen
Germany
Telefon +49 421 3503-0
Telefax +49 421 3503-393
Web www.gestra.de
819311-02/07-2016 kx_mp (808915-02) © GESTRA AG Bremen Printed in Germany
48
9. Sicherheitsventil
9. Safety Valve

Commission-N°:
7001021687
Factory-N°:
4020005 Project:
TIMOR 2
Drawing-N°:
BB2285B
Baujahr: Pos.-Nr.:

Inlet: 1/2" PN 250 - male thread
safety valve
10 12LCA10AA310 1 LESER 4373.2604 Outlet: 1/2" PN 160 female Body 1.4401 / 1.4404 --
set pressure: 27 bar g
thread
Commission-No.:
Customer:

Factory-No.:
4020005 TIMOR 2
Project:
Drawing-No.:
67-3266 BB285B
Project-No.:
Baujahr: Pos.-Nr.:
2021 --
Pos.-No.:
Pos. 10
12LCA10AA310
Type
437
Sicherheitsventile
Metrische Einheiten
Fakten
LWN 461.01-D
Type 437
Ausführungen
Type 437
40 Kappe H2
18 Druckschraube
mit Buchse Axialnadellager 69
19 Gegenmutter
16 Federteller
12 Spindel
54 Feder
2 Austrittsgehäuse
17 Federteller
61 Kugel
7 Teller
1 Eintrittskörper

Gewindeanschluss Gewindeanschluss
Austrittsflansch 2.4
Austrittsadapter 2.1
Eintrittsflansch 48
Flanschanschluss
01/02 LWN 481.01-D

Type 437
Ausführungen und Werkstoffe
Type 437
Werkstoffe
Pos. Benennung Ausführungen Type 4373 Type 4374
1.4104 1.4404
Gewindeanschluss
SA 479 430 SA 479 316L
1.4404 1.4404
1 Eintrittskörper Flanschanschluss
SA 479 316L SA 479 316L
Long version
SA 479 316L stellitiert SA 479 316L stellitiert
1.4104 1.4404
2 Austrittsgehäuse
SA 479 430 SA 479 316L
1.4404 1.4404
2.1 Austrittsadapter Flanschanschluss
316L 316L
1.4404 1.4404
2.4 Austrittsflansch Flanschanschluss
316L 316L
1.4122 1.4404
Edelstahl gehärtet SA 316L
7 Teller
Long version
316L stellitiert 316L stellitiert
1.4021 1.4404
12 Spindel
420 316L
1.4104 1.4404
16/17 Federteller
Chromstahl 316L
Druckschraube 1.4104 / PTFE 1.4104 / PTFE
18
mit Buchse Chromstahl / PTFE 316L / PTFE
1.0718 1.4404
19 Gegenmutter
Stahl 316L
1.0718 1.4404
40 Kappe H2
Stahl 316L
1.4404 1.4404
48 Eintrittsflansch Flanschverbindung
316L 316L
1.4310 1.4310
54 Feder
Edelstahl Edelstahl
1.4310 1.4310
Edelstahl Edelstahl
1.3541 1.4401
61 Kugel
Edelstahl gehärtet 316
1.4404 1.4404
69 Axialnadellager Long version
316L 316L
Bitte beachten:
– LESER behält sich Änderungen vor.

– LESER kann, ohne vorherige Benachrichtigung, höherwertige Werkstoffe einsetzen.
– Jedes Bauteil kann entsprechend der Kundenspezifikation in einem anderen Werkstoff ausgeführt werden.
LWN 481.01-D 01/03

Type 437
How to order – Artikel-Nummern
Type 437
Artikel-Nummern
10
d0 [mm]
78,5
A0 [mm2]
0,394
d0 [inch]
0,122
A0 [inch2]
H2 Art.-Nr. 4373. 2602

H3 Art.-Nr. 4373.
2603
pmax = 10 barg
H4 Art.-Nr. 4373. 2604
p [barg] D/G/F 0,1 – 93
p [psig] D/G/F 1,5 – 1349
H2 Art.-Nr. 4374. 3142
H4 Art.-Nr. 4374. 3144

p [barg] D/G/F 0,1 – 68
p [psig] D/G/F 1,5 – 986
Artikel-Nummern
Long version
6 6 10
d0 [mm]
28,3 28,3 78,5
A0 [mm2]
0,236 0,236 0,394
d0 [inch]
0,044 0,044 0,122
A0 [inch2]
H2 Art.-Nr. 4373. 2622 – 2612
H4 Art.-Nr. 4373. 2624 – 2614

p [barg] D/G/F 180 – 365 – 93 –180
p [psig] D/G/F 2611 – 5294 – 1349 – 2611
H2 Art.-Nr. 4374. 3122 3132 3153
H4 Art.-Nr. 4374. 3124 3134 3154

p [barg] D/G 180 – 365 F 180 – 3801) D/G/F 68 –180
p [psig] D/G 2611 – 4786 F 2611 – 5511 D/G/F 986 – 2611
1) Zurzeitkeine TÜV-Bauteilprüfung, einsetzbar für thermische Expansion.

„Long version“ nur bei Ansprechdrücken die Höher der konventionelle Ausführung liegen.
Für die Auswahl der Eintrittskörper und Austrittsgehäuse siehe Seite 04/04 – 04/05.
LWN 481.01-D 01/07

Type 437
Gewindeanschlüsse
Type 437

1/ " 3/ " 1/ 3/ 1/ " 3/ "
Größe Austrittsgehäuse 2 4 1" 2" 4" 1" 2 4 1"
10 10 10 6 6 6 10 10 10
[mm]
78,5 78,5 78,5 28,3 28,3 28,3 78,5 78,5 78,5
[mm2]
Gewicht [kg] 1,2 1,6 1,6 1,4 2,1 2,1 1,4 2,1 2,1
Benötigter Einbaudurchmesser [mm] 65 80 80 65 80 80 65 80 80
Innengewinde Eintritt
Bauhöhe [mm] H max. 210 220 220 230 240 240 230 240 240
ISO 7-1/BS 21 Rc Eintritt a 45 55 55 45 55 55 45 55 55
Bauhöhe [mm] H max. 210 220 220 230 240 240 230 240 240
Bauhöhe [mm] H max. 210 220 220 230 240 240 230 240 240
Außengewinde Eintritt
ISO 7-1/BS 21 R Eintritt a 31 31 34 31 31 34 31 31 34
Bauhöhe Außengewinde Eintritt

Eintrittsgewinde Größe 3/ 1/ " 3/ " 3/ 1/ 3/ "
8" 2 4 1" 8" 2" 4 1"
DIN ISO 228-1 [mm] G H max. 210 212 214 216 230 232 234 236
ISO 7-1/BS 21 [mm] R H max. – 215 216 219 – 235 236 239
ASME B1.20.1 [mm] NPT H max. – 218 218 223 – 238 238 243
Einschraublänge und Zapfenlänge „c“

Eintrittsgewinde Größe 3/ 1/ " 3/
8" 2 4" 1"
DIN ISO 228-1 [mm] G 12 14 16 18
ISO 7-1/BS 21 [mm] R – 19 20 23
ASME B1.20.1 [mm] NPT – 22 22 27
benötigter Einbaudurchmesser
Konventionelle Ausführung Konventionelle Ausführung Long version

Innengewinde Außengewinde Außengewinde
01/08 LWN 481.01-D
Type 437
Flanschanschlüsse
Type 437
[mm] 6 10 6 10
[mm2] 28,3 78,5 28,3 78,5
DIN ISO 1092-1 (Erhältliche Flanschgrößen siehe Seite 04/05)

Flanschdruckstufe PN 40
Austritt b 100 100 100 100
Bauhöhe [mm] H max. 263 263 284 284
Flanschdruckstufe ≥ PN 160
Austritt b 100 100 100 100
Bauhöhe [mm] H max. 266 266 287 287
ASME B 16.5 (Erhältliche Flanschgrößen siehe Seite 04/05)
Flanschdruckstufe Class 150
Austritt b 100 100 100 100
Bauhöhe [mm] H max. 263 263 284 284
Flanschdruckstufe Class ≥ 300
Austritt b 100 100 100 100
Bauhöhe [mm] H max. 266 266 287 287
Gewicht
Für die Berechnung des Gesamtgewichtes verwenden Sie bitte folgende Formel: mT = mN + mF(Eintritt) + mF(Austritt)
Nettogewicht [kg]
(ohne Eintritts- und Austrittsflansch) mN
2,4 2,4 2,8 2,8
Flanschmaße und Verfügbarkeit

DIN ISO 1092-1 / Flanschdruckstufe PN ASME B16.5 / Flanschdruckstufe
Größe 40 160 250 320 400 Größe 150 300 600 900 1500 2500
DN 15 NPS 1/2"
Flanschblattdicke [mm] s 18 22 26 26 30 14 18 26 30,2
Gewicht Losflansch [kg] mF 0,8 1,2 2,5 2,5 3,6 0,6 0,9 2,1 3
Austrittsseitig erhältlich ✓ ✓ ✓ ✓ ✓ ✓
DN 20 NPS 3/4"
Flanschblattdicke [mm] s 20 22 15 18 25,4 32
Gewicht Losflansch [kg] mF 1,1 1,3 0,8 1,4 2,3 3,5
Eintrittsseitig erhältlich ✓ ✓ ✓ ✓ ✓ ✓
Austrittsseitig erhältlich ✓ ✓ ✓ ✓ ✓
DN 25 NPS 1"
Flanschblattdicke [mm] s 22 26 30 36 40 17 21,5 32,5 40
Gewicht Losflansch [kg] mF 1,3 2,6 3,5 5 7,5 1 2,1 4,1 5,1
Austrittsseitig erhältlich ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓
a
s s
s
s
LWN 481.01-D 01/09

Type 437
Druck- / Temperatur-Einsatzbereiche
Type 437
Metrische Einheiten
6 10
d0 [mm]
28,3 78,5
A0 [mm2]
Anschlussgröße 8" 2" 4" 1" 8 2 4" 1"
Minimaler
Ansprechdruck
Ansprechdruck 180
Anschlussgröße 8" 2" 4" 1" 8 2 4" 1"
Minimaler
Ansprechdruck
Ansprechdruck 180
US Einheiten
0,236 0,394
d0 [mm]
0,044 0,122
A0 [mm2]
Anschlussgröße 8" 2" 4 1" 8" 2 4" 1"
Minimaler
p [barg] D/G/F 2610 1,
Ansprechdruck
p [barg] D/G/F 5294
Ansprechdruck 2610
Temperatur min [°F ] +14 +14
Anschlussgröße 8" 2" 4 1" 8" 2 4" 1"
Minimaler
p [barg] D/G/F 2610 1,5
Ansprechdruck
p [barg] D/G/F 5294
Ansprechdruck 2610
01/12 LWN 481.01-D

Type 437
Zusatzausrüstungen
Type 437
Außengewinde Innengewinde Flanschanschluss
Stellitierte Dichtfläche Teller mit eingesetzter Dichtplatte

J25: Teller stellitiert J44: PTFE-FDA „A“
L20: Eintrittskörper J48: PCTFE „G“
J49: VESPEL-SP1 „T“
Heizmantel
H29
Sonderwerkstoffe Sonderwerkstoffe
2.4360 Monel® 400 2.4360 MONEL 400
Code
YYYY
Code
YYYY
Code Code
Code Code
XXXX ZZZZ
XXXX ZZZZ
01/14 LWN 481.01-D

Type 437
Anwendungsbereich von konventioneller Ausführung und Long version
Type 437
Anwendungsbereich
Long version
D/G/F D/G
Type 4373
Engster Strömungs-
Engster Strömungs- d0 [mm] 10 d0 [mm] 10 durchmesser d0 [inch] 0,236
Strömungs-
durchmesser d0 [inch] 0,394 d0 [inch] 0,394
durchmesser Engster A0 [mm2] 28,3
Engster Strömungs-
Engster Strömungs- A0 [mm2] 78,5 A0 [mm2] 78,5 querschnitt A0 [inch2] 0,044
Strömungs-
querschnitt A0 [inch2] 0,122 A0 [inch2] 0,122
querschnitt
Baugruppe Werkstoffe Baugruppe Werkstoffe
Eintritts- 1.4404 stellitiert
Eintritts- 1.4104 Eintritts- 1.4104 körper SA 479 316L
körper SA 479 430 körper SA 479 430 stellitiert
Teller 1.4122 Teller 1.4122 Teller 1.4404 stellitiert
Edelstahl Edelstahl SA 479 316L
gehärtet gehärtet stellitiert Ansprechdruck
p [psig]
0 986 1349 2611 4786 5294 5511

0 68 93 180 330 365 380
Ansprechdruck
Momentan keine TÜV-Zulassung für
D/G/F D/G thermische Expansion verwendbar.
Type 4374
Strömungs-
Engster Engster d0 [mm] 10 durchmesser d0 [inch] 0,236
d0 [mm] 10
d0 [inch] 0,394 Engster A0 [mm2] 28,3
durchmesser d0 [inch] 0,394 durchmesser
Strömungs-
Engster A0 [mm2] 78,5 Engster A0 [mm2] 78,5 querschnitt A0 [inch2] 0,044
querschnitt A0 [inch2] 0,122 querschnitt A0 [inch2] 0,122
Baugruppe Werkstoffe Baugruppe Werkstoffe Eintritts- 1.4404 stellitiert
körper SA 479 316L
Eintritts- 1.4404 Eintritts- 1.4404
stellitiert
körper SA 479 316L körper SA 479 316L
Teller 1.4404 stellitiert
Teller 1.4404 Teller 1.4404 SA 479 316L
SA 479 316L SA 479 316L stellitiert
01/20 LWN 481.01-D

Type 437 – Seite 01/08 + 01/10
Type 438 – Seite 02/08 + 02/10
Type 439 – Seite 03/08 + 03/10
Außengewinde Innengewinde
Gewindeanschlüsse
Ventilgröße Option code Eintritt Option code Austritt

Außengewinde DIN ISO 228-1
3/
8" V49 ✓ – –
1/
2 " V54 ✓ – –
G
✓
Zusatzausrüstungen
3/
4" V55 – –
1" V56 ✓ – –
Innengewinde DIN ISO 228-1
1/
2" V50 ✓ V65 ✓
G 3/
4" V51 ✓ V76 ✓
1" V52 ✓ V66 ✓
Außengewinde DIN ISO 7-1/BS 21
1/
2" V30 ✓ – –
R/BSPT 3/
4" V31 ✓ – –
1" V32 ✓ – –
Innengewinde DIN ISO 7-1/BS 21
1/
2" V38 ✓ V34 ✓
Rc/BSPT 3/
4" V39 ✓ V35 ✓
1" V40 ✓ V36 ✓
Außengewinde ANSI/ASME B1.20.1
1/
2" V61 ✓ – –
NPT 3/
4" V62 ✓ – –
1" V63 ✓ – –
Innengewinde ANSI/ASME B1.20.1
1/
2" V58 ✓ V70 ✓
NPT 3/
4" V59 ✓ V71 ✓
1" V60 ✓ V72 ✓
04/04 LWN 481.01-D

Type 437 – Seite 01/09 + 01/11
Type 438 – Seite 02/09 + 02/11
Type 439 – Seite 03/09 + 03/11
Flaschanschluss
Flanschanschlüsse

DIN ISO 1092-1 (PN > 100: DIN 2501)
40 I21 ✓ I40 ✓
160 I22 ✓ I41 ✓
✓ ✓
Zusatzausrüstungen
DN 15 250 I23 I42
320 I24 ✓ – –
400 I25 ✓ – –
40 I26 ✓ I43 ✓
DN 20 160 I27 ✓ I44 ✓
250 – – – –
40 I31 ✓ I46 ✓
160 I32 ✓ I47 ✓
DN 25 250 I33 ✓ I48 ✓
320 I34 ✓ – –
400 I35 ✓ – –

ANSI/ASME B 16.5
150 V01 ✓ V24 ✓
300 V02 ✓ V13 ✓
600 V02 ✓ V13 ✓
NPS 1/2"
900 V03 ✓ V14 ✓
1500 V03 ✓ – –
2500 V04 – – –
150 V05 ✓ V15 ✓
300 V06 ✓ V16 ✓
600 V06 ✓ V16 ✓
NPS 3/4"
900 V07 ✓ V17 ✓
1500 V07 ✓ – –
2500 V08 ✓ – –
150 V09 ✓ V18 ✓
300 V10 ✓ V19 ✓
600 V10 ✓ V19 ✓
NPS 1"
900 V11 ✓ V20 ✓
1500 V11 ✓ – –
2500 V12 ✓ – –
LWN 481.01-D 04/05

Type
437
Safety Relief Valves
– spring loaded
Metric Units
Facts
LWN 461.01-E
Type 437
Available designs
Type 437
40 Cap H2
18 Adjusting screw
with bushing Axial needle 69
19 Lock nut beering

16 Spring plate
12 Spindle
54 Spring
2 Outlet body
17 Spring plate
57 Pin
61 Ball
7 Disc
1 Body

Threaded connection Threaded connection
Outlet flange 2.4
Outlet adaptor 2.1
Inlet flange 48
Conventional design
Flange connection
01/02 LWN 481.01-E

Type 437
Available designs – materials
Type 437
Materials
Item Component Remarks Type 4373 Type 4374
Threaded 1.4104 1.4404

connection SA 479 430 SA 479 316L
1.4404 1.4404
1 Base / Inlet body Flange connection
SA 479 316L SA 479 316L
Long version
SA 479 316L Stellited SA 479 316L Stellited
1.4104 1.4404
2 Outlet body
SA 479 430 SA 479 316L
1.4404 1.4404
2.1 Outlet adaptor Flange connection
316L 316L
1.4404 1.4404
2.4 Outlet flange Flange connection
316L 316L
1.4122 1.4404
Hardened stainless steel SA 316L
7 Disc
Long version
316L Stellited 316L Stellited
1.4021 1.4404
12 Spindle
420 316L
1.4104 1.4404
16/17 Spring plate
Chrome steel 316L
Adjusting screw 1.4104 / PTFE 1.4104 / PTFE
18
with bushing Chrome steel / PTFE 316L / PTFE
1.0718 1.4404
19 Lock nut
Steel 316L
1.0718 1.4404
40 Cap H2
Steel 316L
1.4404 1.4404
48 Inlet flange Flange connection
316L 316L
1.4310 1.4310
54 Spring
1.4310 1.4310
57 Pin
1.3541 1.4401
61 Ball
Hardened stainless steel 316
1.4404 1.4404
69 Axial needle beering Long version
316L 316L
Please notice:
– Modifications reserved by LESER.

– LESER can upgrade materials without notice.
– Every part can be replaced by other material acc. to customer specification.
LWN 481.01-E 01/03

Type 437
How to order – Article numbers
Type 437
Article numbers
Conventional design
Actual Orifice diameter d0 [mm] 10
Actual Orifice area A0 [mm2] 78,5
Actual Orifice diameter d0 [inch] 0,394
Actual Orifice area A0 [inch2] 0,122
H2 Art.-No. 4373. 2602

H3 Art.-No. 4373.
pmax = 10 barg 2603
H4 Art.-No. 4373. 2604

p [barg] S/G/L 0,1 – 93
p [psig] S/G/L 1,5 – 1349
H2 Art.-No. 4374. 3142
H4 Art.-No. 4374. 3144

p [barg] S/G/L 0,1 – 68
p [psig] S/G/L 1,5 – 986
Article numbers
Long version
Actual Orifice diameter d0 [mm] 6 6 10
Actual Orifice area A0 [mm2] 28,3 28,3 78,5
Actual Orifice diameter d0 [inch] 0,236 0,236 0,394
Actual Orifice area A0 [inch2] 0,044 0,044 0,122
H2 Art.-No. 4373. 2622 – 2612
H4 Art.-No. 4373. 2624 – 2614

p [barg] S/G/L 180 – 365 – 93 –180
p [psig] S/G/L 2611 – 5294 – 1349 – 2611
H2 Art.-No. 4374. 3122 3132 3153
H4 Art.-No. 4374. 3124 3134 3154

p [barg] S/G 180 – 365 L 180 – 3801) S/G/L 68 –180
p [psig] S/G 2611 – 4786 L 2611 – 5511 S/G/L 986 – 2611
1) At
the moment no TÜV approval, useable for thermal expansion.
Use “Long version” only for set pressure exeeding set pressure range of “Standard” model.
For selection of inlet and outlet connection please refer to page 04/04 – 04/05.
LWN 481.01-E 01/07

Type 437
Type 437

1/ " 3/ " 1/ 3/ " 1/ " 3/ "
Size Outlet body 2 4 1" 2" 4 1" 2 4 1"
Actual Orifice diameter d0 [mm] 10 10 10 6 6 6 10 10 10
Actual Orifice area A0 [mm2] 78,5 78,5 78,5 28,3 28,3 28,3 78,5 78,5 78,5
Weight [kg] 1,2 1,6 1,6 1,4 2,1 2,1 1,4 2,1 2,1
Required installation diameter [mm] 65 80 80 65 80 80 65 80 80
Inlet thread “Female”
DIN ISO 228-1 G Inlet a 45 55 55 45 55 55 45 55 55
Height [mm] H max. 210 220 220 230 240 240 230 240 240
ISO 7-1/BS 21 Rc Inlet a 45 55 55 45 55 55 45 55 55
Height [mm] H max. 210 220 220 230 240 240 230 240 240
Height [mm] H max. 210 220 220 230 240 240 230 240 240
Inlet thread “Male”
DIN ISO 228-1 G Inlet a 33 33 36 33 33 36 33 33 36
ISO 7-1/BS 21 R Inlet a 31 31 34 31 31 34 31 31 34
Height inlet thread “Male”

Inlet thread Size 3/ 1/ 3/ 3/ 1/ " 3/
8" 2" 4" 1" 8" 2 4" 1"
DIN ISO 228-1 [mm] G H max. 210 212 214 216 230 232 234 236
ISO 7-1/BS 21 [mm] R H max. – 215 216 219 – 235 236 239
ASME B1.20.1 [mm] NPT H max. – 218 218 223 – 238 238 243
Length of screwed end “c” inlet thread “Male”

Inlet thread Size 3/ 1/ " 3/
8" 2 4" 1"
DIN ISO 228-1 [mm] G 12 14 16 18
ISO 7-1/BS 21 [mm] R – 19 20 23
ASME B1.20.1 [mm] NPT – 22 22 27
Required installation diameter
Conventional design – Female thread Conventional design – Male thread Long version – male thread
01/08 LWN 481.01-E

Type 437
Flanged connection
Type 437
Actual Orifice diameter d0 [mm] 6 10 6 10
Actual Orifice area A0 [mm2] 28,3 78,5 28,3 78,5
DIN ISO 1092-1 (Available flange sizes refer to page 04/05)
Flange rating PN 40
Outlet b 100 100 100 100
Height [H4] [mm] H max. 263 263 284 284
Flange rating ≥ PN 160
Outlet b 100 100 100 100
Height [H4] [mm] H max. 266 266 287 287
ASME B 16.5 (Available flange sizes refer to page 04/05)
Flange rating class 150
Outlet b 100 100 100 100
Height [H4] [mm] H max. 263 263 284 284
Flange rating class ≥ 300
Outlet b 100 100 100 100
Height [H4] [mm] H max. 266 266 287 287
Weight
For the calculation of the total weight please use the Formular: WT = WN + WF (Inlet) + WF (Outlet)
Weight net [kg]
2,4 2,4 2,8 2,8
(without inlet and outlet flange) WN
Flange dimensions and availability

DIN ISO 1092-1 / Flange rating PN ASME B16.5 / Flange rating class
Size 40 160 250 320 400 Size 150 300 600 900 1500 2500
DN 15 NPS 1/2"
Flange thickness [mm] s 18 22 26 26 30 14 18 26 30,2
Weight slip on flange [kg] WF 0,8 1,2 2,5 2,5 3,6 0,6 0,9 2,1 3
Available at Outlet ✓ ✓ ✓ ✓ ✓ ✓
DN 20 NPS 3/4"
Flange thickness [mm] s 20 22 15 18 25,4 32
Weight slip on flange [kg] WF 1,1 1,3 0,8 1,4 2,3 3,5
Available at Inlet ✓ ✓ ✓ ✓ ✓ ✓
Available at Outlet ✓ ✓ ✓ ✓ ✓
DN 25 NPS 1"
Flange thickness [mm] s 22 26 30 36 40 17 21,5 32,5 40
Weight slip on flange [kg] WF 1,3 2,6 3,5 5 7,5 1 2,1 4,1 5,1
Available at Outlet ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓
a
s s
s s
b
LWN 481.01-E 01/09

Type 437
Pressure temperature ratings
Type 437
Metric Units
Actual Orifice diameter d0 [mm] 6 10
Actual Orifice Area A0 [mm2] 28,3 78,5
Base / 3/ 1/ 3/ 3/ " 1/ " 3/
Connection size 8" 2" 4" 1" 8 2 4" 1"
Minimum
set pressure
Maximum 10 only H3
set pressure 180
Base / 3/ 1/ 3/ 3/ " 1/ " 3/
Connection size 8" 2" 4" 1" 8 2 4" 1"
Minimum
set pressure
Maximum 10 only H3
set pressure 180
US Units
Actual Orifice diameter d0 [inch] 0,236 0,394
2
Actual Orifice area A0 [inch ] 0,044 0,122
Base /
3/ 1/ 3/ " 3/ 1/ " 3/
Minimum
p [barg] S/G/L 2610 1,
set pressure
Maximum 145 only H3
p [barg] S/G/L 5294
set pressure 2610
Temperature min [°F ] +14 +14
Base /
3/ 1/ 3/ " 3/ 1/ " 3/
Minimum
p [barg] S/G/L 2610 1,5
set pressure
Maximum 145 only H3
p [barg] S/G/L 5294
set pressure 2610
01/12 LWN 481.01-E

Type 437
Available Options
Type 437
Male thread Female thread Flanged version
Stellited sealing surface Disc with inserted sealing plate

J25: Disc stellited J44: PTFE-FDA “A”
L20: Base/inlet body J48: PCTFE “G”
J49: VESPEL-SP1 “T”
Heating jacket
H29
Special material Special material

2.4360 Monel® 400 2.4360 MONEL 400
Code
YYYY
Code
YYYY
Code Code
Code Code
XXXX ZZZZ
XXXX ZZZZ
01/14 LWN 481.01-E

Type 437
Application range of conventional design and long version
Type 437
Application range
Long version
S/G/L S/G
Conventional design
S/G/L
Type 4373
Act. Orifice d0 [mm] 10 Act. Orifice d0 [mm] 10 diameter [inch] 0,236

diameter [inch] 0,394 diameter [inch] 0,394 Act. Orifice A0 [mm2] 28,3
Act. Orifice A0 [mm2] 78,5 Act. Orifice A0 [mm2] 78,5 area [inch2] 0,044
area [inch2] 0,122 area [inch2] 0,122
Components Materials Components Materials
Base / 1.4404 Stellited
Inlet Body SA 479 430 Inlet Body SA 479 430 Stellited
Disc 1.4122 Disc 1.4122 Disc 1.4404 Stellited
Hardened Hardened SA 479 316L
stainless steel stainless steel Stellited Set pressure
p [psig]
0 986 1349 2611 4786 5294 5511

0 68 93 180 330 365 380
Set pressure
Also useable above 330 bar (4786 psig) but
S/G/L S/G TÜV requirements will not be fulfilled
Conventional design
S/G/L
Type 4374
Act. Orifice d0 [mm] 10 diameter [inch] 0,236

diameter diameter [inch] 0,394 Act. Orifice A0 [mm2] 28,3
[inch] 0,394
Act. Orifice A0 [mm2] 78,5 area [inch2] 0,044
Act. Orifice A0 [mm2] 78,5
area area [inch2] 0,122
[inch2] 0,122
Components Materials Components Materials Base / 1.4404 Stellited
Inlet Body SA 479 316L Inlet Body SA 479 316L Stellited
Disc 1.4404 Stellited
Disc 1.4404 Disc 1.4404 SA 479 316L
SA 479 316L SA 479 316L Stellited
01/20 LWN 481.01-E

Type 437 – page 01/08 + 01/10
Type 438 – page 02/08 + 02/10
Type 439 – page 03/08 + 03/10
Male thread Female thread

Valve size Option code Inlet Option code Outlet

Male thread DIN ISO 228-1
3/
8" V49 ✓ – –
1/
2 " V54 ✓ – –
G 3/
4" V55 ✓ – –
1" V56 ✓ – –
Options
Female thread DIN ISO 228-1

1/
2" V50 ✓ V65 ✓
G 3/
4" V51 ✓ V76 ✓
1" V52 ✓ V66 ✓
Male thread DIN ISO 7-1/BS 21
1/
2" V30 ✓ – –
R/BSPT 3/
4" V31 ✓ – –
1" V32 ✓ – –
Female thread DIN ISO 7-1/BS 21
1/
2" V38 ✓ V34 ✓
Rc/BSPT 3/
4" V39 ✓ V35 ✓
1" V40 ✓ V36 ✓
Male thread ANSI/ASME B1.20.1
1/
2" V61 ✓ – –
NPT 3/
4" V62 ✓ – –
1" V63 ✓ – –
Female thread ANSI/ASME B1.20.1
1/
2" V58 ✓ V70 ✓
NPT 3/
4" V59 ✓ V71 ✓
1" V60 ✓ V72 ✓
04/04 LWN 481.01-E

Type 437 – page 01/09 + 01/11
Type 438 – page 02/09 + 02/11
Type 439 – page 03/09 + 03/11
Flanged version
Flanged connections
PN Option code Inlet Option code Outlet

DIN ISO 1092-1 (PN > 100: DIN 2501)
40 I21 ✓ I40 ✓
160 I22 ✓ I41 ✓
DN 15 250 I23 ✓ I42 ✓
320 I24 ✓ – –
Options
400 I25 ✓ – –
40 I26 ✓ I43 ✓
DN 20 160 I27 ✓ I44 ✓
250 – – – –
40 I31 ✓ I46 ✓
160 I32 ✓ I47 ✓
DN 25 250 I33 ✓ I48 ✓
320 I34 ✓ – –
400 I35 ✓ – –
Class Option code Inlet Option code Outlet

ANSI/ASME B 16.5
150 V01 ✓ V24 ✓
300 V02 ✓ V13 ✓
600 V02 ✓ V13 ✓
NPS 1/2"
900 V03 ✓ V14 ✓
1500 V03 ✓ – –
2500 V04 – – –
150 V05 ✓ V15 ✓
300 V06 ✓ V16 ✓
600 V06 ✓ V16 ✓
NPS 3/4"
900 V07 ✓ V17 ✓
1500 V07 ✓ – –
2500 V08 ✓ – –
150 V09 ✓ V18 ✓
300 V10 ✓ V19 ✓
600 V10 ✓ V19 ✓
NPS 1"
900 V11 ✓ V20 ✓
1500 V11 ✓ – –
2500 V12 ✓ – –
LWN 481.01-E 04/05

Betriebsanleitung Operating instructions
Ausgabe Oktober 2005 October 2005 edition
Instructions de service Instrucciones de servicio

Edition octobre 2005 Edición octubre 2005
40
18
16
12
H
54
55
56
60
NPSOutlet
DNAustritt
7
a
do
DNEintritt
NPSInlet
b
The Safety Valve

E
40 Lifting device
18 Adjusting screw
16 Spring plate
9 Bonnet
12 Spindle
H
54 Spring
55 Stud bolt
56 Hexagonal nut
60 Seal
NPSOutlet
DNAustritt
8 Guide
7 Plate
Seat
a
1 Body
do
DNEintritt
NPSInlet
b
18
1 Contents The following risks could ensue:

a.) The safety valve does not work correctly or is
1 Contents 17 dimensioned incorrectly: the pressure
2 General 17 equipment bursts. Hazard caused by the
3 Testing/marking 17 bursting itself and by the hot, poisonous and
4 Pressure 18 aggressive medium.
5 Function of a safety valve 18 b.) The safety valve operates correctly; medium
6 Functional tightness of a safety valve 19 escapes: there is a risk of hot, poisonous
7 Medium 19 and aggressive medium.
8 Temperatures of the medium and ambient c.) The safety valves leaks: there is a risk of hot,
temperatures 20 poisonous and aggressive medium.
9 Choice of spring 20 d.) Other dangers caused by handling the safety
10 Safety valves with bellows 21 valves e.g., risk of injury from sharp edges, E
11 Safety valves with blow-down ring 21 heavy weight, ...
12 Safety valves built into installations 21
12.1 Open bonnet 21 In order to minimise the risks of these hazards,
12.2 Regular lifting operation 21 the operating instructions must be adhered to at
12.3 Forces acting on the safety valve 21 all times and given priority over the
12.4 Connections 21 recommendations below. The operating
12.5 Direction of safety valves 21 instructions have been developed by practical
12.6 Flow-through 22 experience and from the requirements stipulated
12.7 Condensation 22 in the regulations.
12.8 Transfer of vibrations from the installation 22
12.9 Discharge pipe 22 Sets of rules and standards:
12.10 Unfavourable environmental conditions 23 • Pressure Vessel and Steam Boiler Ordinance
12.11 Leaks caused by foreign bodies 23 • TRD 421, 721
12.12 Protection during storage and transport 23 • TRB 403
12.13 Corrosion protection 23 • AD 2000-Merkblätter A2 and A4
12.14 Maintenance 23 • DIN EN ISO 4126
12.15 Identification of safety valves 23 • Pressure Equipment Directive 97/23/EC
12.16 Lever safety valves 23 • ASME Code Section II and VIII
13 Setting instructions for spring loaded • API 526, 520, 527
safety valves 23 • Others.
13.1 Lifting device H3 23
13.2 Lifting device H4 24 LESER is in possession of the appropriate
13.3 Spring replacement 24 product-related certificates to prove that the sets
14 Handling 25 of rules and standards are fulfilled and that safety
15 Supplementary loading system 25 is therefore guaranteed.
16 Combined Safety Valve and Bursting Disc 26
17 Unexpected conditions 26 LESER is certified according to:
18 Product overview 26 • DIN EN ISO 9001/2000 (Quality Management
19 Assembly instructions 26 System)
20 Disclaimer 26 • DIN EN ISO 14001/2005 (Environmental Manage-
ment System)
• Modul D of the Pressure Equipment Directive
2 General (quality assurance in production)
• ASME VIII (UV) and
The following general notes refer to directly • KTA 1401
loaded and controlled safety valves (with This ensures that all requirements for quality and
supplementary loading system). environment are complied with.
To fulfill its function all components of a safety

valve are manufactured to great precision. Only 3 Testing/marking
this precision allows correct functioning. Safety
valves must therefore be handled with care. After setting and testing, each safety valve is
Failure could endanger people, animals and sealed by LESER or by the expert of an official
installations. Even with a correctly functioning acceptance organisation at the customer’s
safety valve hazards may occur. This has to be request (such as TÜV, Germanischer Lloyd, ...).
taken into account.
If the marking of the safety valve is applied on the
valve body by means of a marking stamp, the
safety valve must not be damaged by such
stamping. Deformation of the valve may cause
leakage or destruction of the safety valve. Thin-
19
walled valve bodies should not be stamped. produced, which acts on the rear side of the disc.
This increases the set pressure by exactly the
Safety valves have a name plate showing the value of this pressure. If the superimposed back
following data: pressure is constant, it is possible to adjust the
• Date of order (Serial-No.) differential pressure by reducing the value of the
• Technical data test pressure by the value of the back pressure
• Test pressure (test pressure set pressure).
• VdTÜV type test approval number
• CE-marking and identification number of the If there is no superimposed back pressure, the
notified body. set pressure will drop. The back pressure
intended must not be exceeded because then it
For safety valves without type test approval, only would also exceed the set pressure.
E order data and technical data are included.
The maximum pressure that a safety valve may
Further marks required are either moulded into
be operated at regardless of the test pressure
the casting, or, for safety valves with threaded
depends on a number of factors.
connections, punched in. Safety valves with a
Among these are:
heating jacket have a separate name plate for the
• Materials
heating jacket.
• Medium temperature
If technical changes are made, always check • Design pressure
whether the identification has to be adjusted. • Flange classes
Modifications on valves or identifications may • Others.
only be carried out by trained personnel (refer to
section 12.14). These should be taken into consideration when
selecting a safety valve.
4 Pressure The value of the operating pressure must

permanently be lower than the reseating pressure
Definitions: difference plus 5%. Otherwise LESER cannot
a) Test pressure: the pressure that the safety guarantee that the valve will close securely after
valve is set to at LESER’s. The outlet side of the opening (exception: if the valve is fitted with a
safety valve is open to atmospheric pressure. supplementary loading system, refer to section 15).
b) Set pressure: the predetermined pressure at
which a safety valve under operating
conditions commences to open. 5 Function of a safety valve
c) Overpressure: a pressure increase over the
set pressure, at which the safety valve attains A performance certificate is required to ensure
the lift specified by the manufacturer, usually that the required mass flow is discharged by the
expressed as a percentage of the set safety valve if necessary.
pressure.
d) Reseating pressure: the value of the inlet Pipes leading to the safety valve have to be fitted
static pressure at which the disc re- so that large hydrodynamic losses are prevented.
establishes contact with the seat or at which The edges at the pipe inlet should be at least
the lift becomes zero. chamfered, but preferably rounded. The notes on
e) Operating pressure: the pressure at which dimensioning given in the regulations, standards
the plant operates. and manufacturer’s information sheets must be
f) Built-up back pressure: the pressure existing adhered to.
at the outlet of a safety valve caused by flow
through the valve and the discharge system. Safety valves may only be disabled by means of
g) Superimposed back pressure: the pressure shut-off valves provided that the pressurised
existing at the outlet of a safety valve at the equipment is protected against excessive
time when the device is required to operate. pressure by other safety devices or that the plant
h) Back pressure: the total of built up and or equipment is shut down altogether.
superimposed back pressure.
Safety valves are guaranteed to work perfectly, if
Pressure shall be stated as overpressure [bar g or
the built-up back pressure on the outlet side does
psig] above atmospheric pressure.
not exceed 15% of the test pressure minus the
Unless stated otherwise, the pressure specified superimposed back pressure (if available).
by the customer is set with atmospheric pressure
acting on the outlet side (test pressure = set Built-up and superimposed back pressures may
pressure). be compensated by an amount not exceeding
35% of the set pressure by using stainless steel
If there is pressure on the outlet side bellows specially designed for this, which
(superimposed back pressure), a force is compensates the force acting on the rear side of
the disc. Function and set pressure remain
20
constant. If it is not clear whether the bellows Sealing surfaces are machined with great
compensate for pressure, LESER should be precision. A tight seal is achieved, for instance,
contacted. The application limits of the bellows by hardening, tempering, precision-grinding and
for pressure and temperature must not be lapping. This makes safety valves vulnerable to
exceeded (refer to section 10). impact damage; they may, for example, develop
leaks as a result of vibrations.
If discharge lines are fitted with equipment, which
prevents the ingress of rainwater or foreign The following notes are to be observed:
bodies, such equipment must not obstruct or • During transport, installation and operation
restrict the outlets of the safety valve. safety valves must be protected from vibra-
tions.
The blow-off pipe should be dimensioned using • Safety valves must be transported with care, e.g.,
the maximum back pressure and the appropritate the lever must never be used as a carrying handle E
temperature. It should be installed in a pipe run, and the safety valve must not be dropped.
which is free from restrictions and turbulences
and should not be opposite other branches, to The force between the seat and the disc falls as a
ensure that it does not impair the functioning of function of rising operating pressure. Therefore
the valve or damage it. The capacity and the probability of leaks also rises if the operating
functioning of safety valves must also be ensured pressure is close to the set pressure (refer to
in applications, where blow-off systems fulfill section 4). Damaged or contaminated sealing
several functions. surfaces in particular tend to develop leaks.
During blowing-off, reaction forces act on the

safety valve itself, the pipes connected to it and 7 Medium
the fixed mounts. The size of the reaction force is
particularly important for the dimensioning of the Any moving parts have to be protected from
fixed mounts. abrasive/corrosive media to avoid the risk of
jamming, seizing or sticking. This can be done by
The following points have to be taken into con- servicing the valve each time it has opened or by
sideration: using stainless steel/elastomer bellows. The
• Static, dynamic or thermal loads exerted by the limits of application for the bellows have to be
pipe leading to or from the safety valve must observed.
not act on the valve.
• Safety valves must be fixed as specified in the The possibility of leaking sealing surfaces caused
drawing. Omitting or removing mounts can by abrasive media must be considered.
result in damage because this results in Dangerous media must not be allowed to enter
excessively large forces or tensions. the environment. In case of doubt the safety valve
• Also refer to section 12.3. should be replaced after opening.
Soft sealing discs can compensate for minor

6 Functional tightness of a safety valve damage to the seat. In every case the limits of
application and medium consistency for the
One has to expect a slight leakiness with all elastomer material have to be observed.
safety valves fitted with metal seals. People,
environment and installations must not be The strength of components (e.g. body, spindle,
endangered by the escaping medium. spring) may be reduced by abrasion. This may
lead to leaking or to the bursting of pressure
Safety valves with soft seals seal are much more equipment. If abrasive media are used, main-
reliable than those with metal soft seals. LESER tenance intervals should be shortened.
offers a range of elastomer materials for different
applications. The elastomers must match the Sealing surfaces must not stick together.
medium and its pressure and temperature. This can be prevented by:
• Regular lifting operation (refer to section 12.2)
All LESER products are inspected for damage • Heating or cooling to prevent the seat from
and leaks. In order to prevent damage during sticking
transport all products have their flange faces, • Other measures which prevent sticking.
sealing lips and pipe threads protected before
being packed for shipment. This protection Corrosion damage to body parts and inner parts
should be removed before assembly (refer to cannot always be spotted easily. Therefore the
section 12.12). user must make sure that the medium does not
attack or corrode the materials the safety valve is
Before installing the valve in the plant or pipeline made from. If this possibility cannot be excluded,
system it should be inspected for damage. Once monitoring and servicing have to be adapted to
installed, the valve should be checked for leakage this situation accordingly. Special materials can
while the plant or pipeline system is operating. be selected on request.
21
Lubricants based on mineral oils are used as an Contact with hot or dangerously cold safety valve
aid during installation. These fluids can surfaces must be prevented by appropriate
contaminate the medium unless special protective measures.
precautions are taken.
The following points have to be observed:
• Lubricants/auxiliary fluids can reach the 9 Choice of spring
medium and contaminate it or cause a chemical
reaction. The springs used by LESER are designed for
• Lubricants can be washed out and make the defined pressure ranges. The test pressure is
dismantling of the safety valve more difficult. always the basis for selecting the spring (refer to
• Safety valves can be designed as oil and section 4). The functioning of the springs is
grease-free types. For these types of valves all ensured if the spring is designed and used in
E residues containing mineral oil are removed conformity with the sets of rules.
from the valve sufaces and special lubricants
are used. When dismantling the valves, the springs must
• Bellows prevent contact between medium and not be mixed up as the functioning will be
lubricant. impaired, if the wrong spring is installed. In
extreme cases the spring will be fully
compressed (the coils touch each other) and the
8 Temperatures of the medium and ambient safety valve does not work.
temperatures
When changing the test pressure the user must
Minimum and maximum temperatures are given check whether the spring/springs can be used at
for LESER safety valves. They always refer to the the new pressure. This can be done by using
temperature of the medium, which may current LESER spring tables. If they are not
simultaneously be the ambient temperature. available please contact LESER. If the spring is
Therefore, the ambient temperature has to be not suitable for the new test pressure it must be
taken into consideration under extreme climatic replaced by a suitable spring. If the test pressure
conditions such as are found in Scandinavia. of a safety valve is altered, the whole safety valve
and its dimensioning must be checked for
It is necessary to observe the effect of suitability.
temperatures of the medium on the maximum
permitted pressure. If expansion limits drop at LESER springs bear clear identification marks.
higher temperatures or if the medium tends to be Springs which can no longer be identified or
brittle at low temperatures, the maximum permitted damaged springs must not be used.
temperatures must be lowered. Please observe the
specifications/regulations in the appropriate sets of Springs must not be reused if it cannot be
rules and the manufacturer’s specifications. estimated how many load changes they have
been subjected to. This applies in particular to
If the safety valve is supposed to be thermally the springs of safety valves which have been
insulated, the bonnet and the cooling zones (if exposed to vibrations, as in this case the actual
there are any) must not be covered to protect the number of load changes is practically impossible
springs from becoming overheated. to estimate.
To set a safety valve for a particular pressure at a The springs used in LESER safety valves have
higher ambient temperature, a correction factor been matched to the materials used in these
should be used to allow for the increased valves. In unfavourable cases, there may be
temperature. This eliminates the necessity of factors leading to increased temperature or
adjusting the setting while the medium is at the corrosion that make the following actions
higher temperature (procedure: Cold differential necessary:
test pressure according to LESER work standard Temperature effects:
LWN 001.78). As spring temperatures depend on many external
conditions, no general temperature of the medium
During the operation of safety valves, medium can be specified as the limit of application. It has
can freeze, which prevents opening and closing. to be evaluated in every single case, which of the
This can happen if the temperature falls below following measures need to be taken:
the freezing point of the medium. In case of • Using spring materials that are heat resistant or
media, which congeal at low temperatures, the tough at subzero temperatures
viscosity may drop significantly. If the medium • Providing the test pressure with a correction
contains freezing vapours, the risk of icing-up is factor to compensate for a drop of set pressure
increased by the expansion of gases as this at higher temperatures (refer to section 8 for
causes the temperature to fall further. If there is cold adjustment)
danger of icing, measures must be taken to • By using highly heat-resistant materials in
ensure that the safety valve works correctly. conjunction with cooling zones, open bonnets
22
and bellows, the effect of the temperature on movable parts (e.g., the spring) as otherwise
the spring is reduced. there is a danger of jamming. Medium can leak
out of the open bonnets or open spindle guides
Corrosion effects: of lever safety valves. The user must ensure
• Medium may enter into the spring chamber if that leaking medium cannot cause hazards.
safety valves do not have bellows. Corrosive/ A sufficient safety distance has to be observed.
abrasive media reduce the fatigue strength.
This should be taken into consideration when 12.2 Regular lifting operation
selecting, sizing and servicing safety valves. Safety valves must be vented regularly in order
• Spring materials with increased corrosion to check their function and to remove residues.
resistance may be used (e.g., stainless steel, They can be opened if at least an operating
Hastelloy, ...) pressure of ≥ 75% of the set pressure is
reached. Exceptions can only be allowed if the E
functioning is checked regularly in a different
10 Safety valves with bellows way, e.g., by appropriate short maintenance
intervals. The valid regulations for the
The pressure and temperature application limits application of safety valves have to be adhered
of bellows must be complied with. to.
Defective bellows are recognisable by the After lifting, the lever must move freely, i.e. the
medium leaking out of the open bonnet or the lifting fork in the lifting device must not acting
vent hole. Hazards from leaking medium must be on the spindle cap.
prevented.
12.3 Forces acting on the safety valve
Measures against leaking medium: Safety valves must not be subjected to
• Equipping the valve with an inspection excessive static, dynamic or thermal stresses.
manometer and a drip container. These can be caused by:
• In the case of open bonnets, the leaking of the • Installation under tension (static)
medium cannot be prevented if the bellows are • Reaction forces when blowing off (static)
defective. Hazards have to be prevented, (e.g., by • Vibrations (dynamic)
a sufficient safety distance, protection equipment • Temperature expansion (thermal)
or by using only non-hazardous media).
The following precautions should be taken:
Defective bellows must be replaced immediately • The system must be able to expand
in order to ensure the correct function of the • Pipe runs must not be fixed in a way that
safety valve. they are under tension.
Stainless steel bellows for which the number of • The safety valve brackets should be used for
permitted load changes has been exceeded, or is attaching the valve securely to the plant.
unknown, must be replaced. As a rule bellows • Vibration of the safety valve and plant should
should be replaced whenever the valve is dis- be prevented.
mantled.
12.4 Connections
Moisture or dirt must not be allowed to enter the The connections/seals between the safety valve
bonnet via the vent hole. Appropriate protective and the plant shall be of sufficient size. They
measures (e.g., connections, pipes,...) must be also have to be designed in accordance with
taken. the sets of rules to prevent the connection from
failing (also refer to sections 4 and 8).
11 Safety valves with blow-down ring The user is responsible for the correct fitting of
seals for pipes leading into the valve and pipes
Safety valves with blow-down ring, like type 526, for blowing-off or other connections to the
are always delivered with the blow-down ring in safety valves. Therefore LESER will not accept
the lowest position. That is, that the blow-down any liability for these.
ring is screwed into the nozzle, until the lower
stop is reached. The blow-down ring is arrested For correct installation the user should ensure
with a lock screw, which is sealed. The position that the flange sealing surfaces are not
of the blow-down ring must not be changed. damaged during installation.
12.5 Direction of safety valves

12 Safety valves built into installations Confirmation by the TÜV Nord:
Directly-loaded safety valves are to be installed
12.1 Open bonnet in accordance with AD 2000-Merkblatt A2
For open bonnets or lever valves, appropriate “upright with respect to the flow direction”:
measures must be taken to avoid contact with
23
In addition AD 2000-Merkblatt A2 requires that • The blow-off pipe must be provided with a
“safety valves must correspond to the state-of- sufficiently large condensation drainage pipe,
the-art and be suitable for the purpose for which must be attached to the lowest point
which they are deployed”. of the pipe. For pipes larger than nominal
diameter 40 mm the drainage pipe must
Under the following conditions it is possible to have a nominal diameter of at least 20 mm.
deviate from the upright installation direction, (In case of steam applications even larger
and in our view it is also permissible. diameters may be necessary. In such cases
E.g., the safety valves have been granted type the regulations must be observed).
approval for non-upright installation and a note • LESER safety valves are not provided with a
to this effect is found in the VdTÜV-Merkblatt. drain hole as the drainage must be executed
If adequate experience of installing safety valves via the blow-off pipe.
E in a direction other than upright is available over Exceptions: Certain regulations require
an extended period, this type of installation drainage holes (e.g., on ships with variable
is permissible if agreed between operator, orientation in the water and a pipe slope).
manufacturer and the technical inspector, who Safety valves which are intended for such
authorises the installation. If applicable, purposes are equipped with a drainage hole.
additional measures may need to be taken with Such designs are only manufactured if they
regard to this installation. are specifically ordered.
• It is possible to drill a drain hole later at the
Therefore safety valves may, according to the place intended for this purpose.
information provided above, be installed in Caution: swarf can cause damage which
directions other than the one specified in AD may lead to leaks or to the failure of safety
2000-Merkblatt A2. valves.
• Drainage pipes must be installed sloping
If the conditions mentioned above have been downwards; these pipes must have no
fulfilled, the following points have to be restrictions such as locally reduced
observed when installing the valve in a direction diameters. There must be an unobstructed
other than upright: view of the drain outlet; any risks resulting
• Drainage has to be fitted to drain medium or from leaking medium must be prevented.
condensation from components which are (e.g., by fitting condensation traps, drip
important for the function of the valve. container, filters, etc.)
• Servicing procedures should be modified, • Unused drainage holes must be closed.
e.g., the functioning of the drainage system
must be ensured.
• LESER must be informed about the type of 12.8 Transfer of vibrations from the installation
installation in order to be able to agree to a Any vibrations which might be transferred to the
direction deviating from upright. safety valve must be prevented. If this is not
possible the safety valve must be decoupled
12.6 Flow-through from the installation, e.g., via bellows, pipe
The flow direction must be observed during bends, ...
installation. It can be recognised by the
following features: Pressure variations or surges in the medium
• Flow direction arrow on the body also may lead to dangerous vibrations of the
• Diagrams in the safety valve. This also has to be prevented.
– Complete Catalogue
– Operating instructions If the transfer of vibrations cannot be
– Data sheets and prevented, damping systems can be built in,
– Assembly instructions. e.g., o-ring dampers.
12.7 Condensation 12.9 Discharge pipe

Medium or condensation must be drained from When a safety valve blows off, in addition to the
the outlet chamber of the safety valve or such general hazards from the medium, the following
components, which are important to the hazards have to be expected (refer to section 2):
functioning of the valve (spring, bellows etc.). • High flow rates
• High temperatures
The following points should be noted: • Noise emissions
• Drainage should always be carried out via the
blow-off pipe, which should be installed sloping In this context the following points should be
downwards so that it can drain itself (figure 3). noted:
• Directly downstream of the safety valve there • For steam or gases the blow-off pipe should
must be no upward bend as in this case point upwards in order to allow blowing off
correct drainage would not be possible without danger.
(figure 4).
24
• For liquids the blow-off pipe should point In the case of lever safety valves, the wooden
downwards so that the medium can wedge, which protects the sealing surfaces
completely drain out of the blow-off from damage during transport, has to be
chamber. removed.
• The outlet flange of safety valves or blow-off
pipes must be directed so that no danger is 12.13 Corrosion protection
caused by the medium blowing off. The Moving parts and parts important to the
following options are available: operating of the valve must not be impaired in
- Blowing off into a container their motion, e.g. the blowing-off chamber. The
- Safety valve and blowing-off pipes without spindle guide must not be varnished.
direct access
- Design with silencer. The supplementary loading system must not be
coated with protective paint (refer also to E
12.10 Unfavourable environmental conditions section 15).
All LESER safety valves which may corrode are
coated with a protective coating during 12.14 Maintenance
manufacture which protects the safety valve Safety valves may only be serviced by skilled
during storage and transport. In corrosive staff.
environments a further corrosion protection is
required (refer to section 12.13). For extreme Maintenance intervals cannot be specified by
conditions, LESER recommends stainless steel LESER as they depend on many factors:
safety valves. The supplementary loading • Corrosive, aggressive and abrasive media
system must not be given a protective coating! lead to rapid wear and require shorter main-
tenance intervals
External media (e.g., rain water or dirt/dust) • Frequent operating requires shorter main-
must not enter the blowing-off pipe or come in tenance intervals
contact with functional components (e.g., • Maintenance intervals have to be agreed
guides with open bonnets) have to be avoided. between the operator, the inspector and the
By analogy, the statements made in section 7 manufacturer. Inspections must be carried
apply. out at the time of the regular external and
Simple preventive measures are possible: internal checks of the pressure equipment.
• Protection of the blow-off chamber from
extraneous media and dirt 12.15 Identification of safety valves
Before assembling safety valves the
• Protection of the parts important to documentation must be checked in order to
operating from external media and dirt. ensure that the correct valve has been selected
for the assembly.
12.11 Leaks caused by foreign bodies
Foreign bodies must not remain in the 12.16 Lever safety valves
installation (e.g., welding beads, sealing The set pressure of lever safety valves is
material such as hemp tape, PTFE tape, defined by the mass and the position of the
screws, etc.). One option for avoiding foreign loading weights. It is not allowed to change
bodies in the system is to flush it before them.
commissioning. No additional loading weights must be added.
The lever must not be used for suspending any
If leaks are caused by contamination between parts, e.g. for hanging clothes on.
the sealing surfaces, the safety valve can be
vented to clean the surfaces. If this does not
stop the leak, one of the sealing surfaces is 13 Setting instructions for spring loaded safety
probably damaged. In this case the safety valve valves
has to be serviced.
The following operating instructions only apply
12.12 Protection during storage and transport to valves without additional equipment. If there
All protective devices for transport and handling is additional equipment (such as O-ring
have to be removed before installing the safety dampers, proximity switches, bellows, ...)
valve. please refer to the corrosponding assembly
instructions.
After installation, the protection for the lever
must be removed from the bonnet as otherwise 13.1 Lifting device H3
the safety valve cannot be vented. The lever 1. Remove shaft (40.4).
must move freely, i.e. it must be in its initial 2. Pull lever (40.6) out to the side.
position and the coupling at the spindle must 3. Loosen hexagonal head screw (40.3).
not be connected to the lever. 4. Unscrew and remove lever cover (40.1).
25
5. Loosen lock nut (19). 5. Loosen the lock nut (19) of the adjusting
6. 1) Turn adjusting screw (18) to the required screw (18).
set pressure. 6. 1) Turn the adjusting screw (18) anticlock-
Pay attention to the admissible pressure wise to remove all spring tension.
range of the spring! 7. Remove the hex. nuts (56) from the flange
Clockwise turning of adjusting screw of the bonnet (9).
increase the spring tension, giving a higher 8. Lift off the bonnet (9).
set pressure. 9. Remove the upper spring plate (16).
Anticlockwise turning of adjusting screw 10. Lift off the spring (54) and remove lower
reduces the spring tension, giving a lower set spring plate (16) and split rings (14).
pressure. 11. Remove spindle (12) with guide (8) and
7. Reassemble in reverse order and lock at the disc (7).
E set pressure. 12. Carefully clean seat (5) and disc (7), and if
required body internals.
19 13. Refit spindle (12) with guide (8) and disc (7).
40.4 19
14. Fit the split rings (14) into spindle groove
40.1 and retain with the securing ring (59); slip
40.3
40.3 on lower spring plate (16) to locate on split
18
rings (14).
40.6
40.6
15. Replace spring (54).
16. Slip on the upper spring plate (16) onto the
spindle (12).
17. Align adjusting screw (18), and bonnet (9).
Fig. 1
over the spindle (12) and refit.
18. Fit and tighten the hex. nuts (56).
13.2 Lifting device H4 19. 1) Load the spring (54) to obtain the required
1. Loosen the spring cover (40.1.1) and set pressure. Clockwise rotation of
simultaneously press the lever (40.1.6) in the adjusting screw (18) increases pressure.
direction of the bonnet so that the lifting fork Anticlockwise rotation of adjusting screw
(40.1.5) comes free. (18) reduces pressure.
2. Remove the lever cover (40.1.1). 20. Tighten the lock nut (19) onto the adjusting
3. Loosen the lock nut (19). screw (18).
4. 1) Turn adjusting screw (18) as described in 21. Refit and secure spindle cap (40.12) by pin
lifting device H3. Pay attention to the ad- (40.13) and securing ring (40.14).
missible pressure range of the spring! 22. Screw-on the lever cover (40.1).
5. Reassemble in reverse order and lock at the 23. Pull the lever (40.6) towards the middle so
set pressure. that the lifting fork (40.5) is pushed under
the spindle cap (40.12).
24. Test spindle will lift correctly by pulling
40.1.6
lever.
40.1.5
18 These instructions are applicable for relief valves,
safety valves and safety relief valves.
40.1.1
19 1)Caution: During all work the spindle has to be
secured against twisting in order to prevent
damage to the sealing surfaces.
Fig. 2
13.3 Spring replacement The following points should be noted:

The following items refer to the figures shown in The pressure setting is wire-locked and
the LESER Product Catalogue. sealed against unauthorized alteration. The
rules and standards, agreed by the manu-
1. Loosen the existing lead seal. facturer, require the fitting of a name plate
2. Press the lever (40.6) towards the middle stating the correct valve data. The manu-
until it reaches the stop so that the lifting facturer cannot be held responsible for any
fork (40.5) no longer holds the spindle cap changes to set pressure or other alterations
(40.12). after despatch from the factory. Necessary
3. Loosen and remove the lever cover (40.1). modifications should only be made by
4. Loosen the spindle cap (40.12) from the authorised distributors of LESER or under the
spindle (12), remove the securing ring supervision of the TÜV or any other
(40.14) and the pin (40.13). competent inspection authority.
26
14 Handling 15 Supplementary loading system
There is a risk of injury from sharp edges and Even if the external energy supply (compressed
burrs. For this reason all parts have to be handled air) fails, the direct-loaded safety valve is still fully
with caution. functional. In this case the function is equivalent
to the LESER standard safety valve without
There is a risk from safety valves falling over. supplementary loading system.
They always have to be secured adequately.
The compressed air filter must be serviced at
During dismantling the spring must not be regular intervals as specified in the maintenance
tensioned. Otherwise there is danger of injury instructions.
from flying parts. Observe the assembly
instructions for the relevant safety valves! The installation should contain an air dryer. The E
compressed air should have a dew-point of
Before dismantling you should always check minimum +2 °C.
whether there is, or could be, any medium in the
bonnet; also check what the medium is. The maximum pressure of the air supply is 10
bar, the minimum pressure is 3.5 bar. If the
There is a great risk of injury, chemical burns pressure rises above or falls below the specified
or poisoning if there is any remaining medium interval, this may lead to temporary or permanent
inside the safety valve. failure of the supplementary loading system. As a
result the safety valve does not function or it
One should use conventional high quality tools in will work as a standard valve without the
order to minimise the risks arising from bad supplementary loading system.
quality tools or inadequate tools. Any necessary
special tools are indicated in the assembly The supplementary loading system should be
instructions. serviced and checked at least once a year by
specially trained staff. For this essential work
Safety valves may only be dismantled and LESER offers a maintenance service which may
assembled by skilled staff. be incorporated in a service agreement. Training
The training can be carried out: and experience with handling the supplementary
• In the workshop by experienced staff loading system in combination with the safety
• At LESER training seminars valves are essential.
• By means of LESER documentation, e.g., The supplementary loading system has to be
videos, operating instructions, catalogues, fitted in accordance with the rules and standards
assembly instructions and the specifications distributed by LESER. If
serviced correctly, failures due to contamination
The maintenance staff must be informed about of the pressure and control lines can be ex-
the risks during dismantling and installing the cluded.
safety valves.
The control unit is to be protected from
Contamination and damage to the safety valve contamination. It has to be ensured that it is
must be avoided. Suitable cartons, protective always closed. For special applications LESER
covers for the flanges, wrapping foil, shipping offers an encapsulated box sealing the control
palettes etc. have to be used. The packaging unit.
must be completely removed before installation
as otherwise the function of the safety valve The actuator on the safety valve itself as well as
cannot be guaranteed. sliding parts inside an open bonnet must be
Safety valves have to be handled with care as protected from contamination. Otherwise there is
otherwise the vulnerable sealing surfaces can be the danger of jamming.
damaged or the safety valve might even be
rendered useless. Temperatures:
The controls and actuators are designed for
Safety valves must be stored in a dry place. The applications between 2 °C and 60 °C.
optimum storage temperature is 5 °C to 40 °C. • At temperatures above 60 °C the compressed
For o-ring discs temperatures below freezing air connections must be as long as possible
should be avoided, if possible. The temperature and equipped with a water seal.
resistance, in particular of the o-ring materials, • The control unit and actuators have to be
has to be taken into account. positioned in a way that their temperature will
Upper limit for storage: 50 °C not exceed 60 °C.
Lower limit for storage: -10 °C • At a temperature below 2 °C there may be
danger of icing-up, therefore it may be
necessary to heat control unit, control lines and
tapping lines.
The supplementary loading system is
27
connected to the safety valve via a coupling. The 17 Unexpected conditions

coupling must not be blocked by objects. It is
neither necessary nor permitted to apply a Not all errors can be prevented entirely.
protective coating to the actuator.
However, their consequences must be estimated
The pressure tapping lines must not be shut off. If and reduced by:
there are shut-off devices they have to be • A risk analysis for the complete installation
designed in such a way that they cannot be • An estimate of the risk and potential damage
closed, e.g., by means of locking bars or seals. • Instructions about the measures to be taken in
the case of malfunctioning
LESER control units are equipped with a shut-off • Staff training at the manufacturer’s and at the
device for maintenance purposes. They are operator’s
E secured against shutting-off by means of a • Protective measures for people and for the
locking bar. This locking bar must not be environment.
removed.
The pressure switches are wire-locked and 18 Product overview

sealed. This seal indicates that the setting has
not been changed. It is not permitted to For the product overview please refer to the
manipulate the pressure switches (e.g., by “Declaration of conformity”.
opening the seal and modifying the adjustment or
by opening the switching contacts, ...)!
19 Assembly instructions
If a test gag is used during pressure testing of the
installation it must be removed after the test. In addition to the Operating Instructions there is a
number of type-specific assembly instructions,
which are listed in the “Request form LESER
16 Combined Safety Valve and Bursting Disc Assembly Instructions”.
The type test approval of the combination of In detail the type-specific assembly instructions
bursting discs of a certain manufacturer with have to be observed.
LESER safety valve ensures that both the
functional and performance requirements are
met. If you require information on the tested 20 Disclaimer
combinations, please contact LESER.
The manufacturer reserves the right to make
Combinations of LESER safety valves and technical changes or improvements at any time.
bursting discs of other manufacturers are per-
missible, if they meet the safety requirements.
This shall be certified for each individual case.
The following points should be noted in

particular:
• Operating instructions for the bursting disc.
• Safety valves must not lose their function by
placing the upstream bursting disc.
• The space between the rear side of the bursting
disc and safety valve inlet should be monitored.
• The bursting disc should be designed in a way
that it cannot be installed incorrectly.
• The bursting disc has to open free of
fragments. Bursting disc components must not
enter the inlet connecting pieces of the safety
valve thus impairing the function.
• Sets of rules with reference to bursting discs
(AD 2000-Merkblatt A1, ASME, ...)
28
additional drain pipe

in case of prepared
drainhole
E
incorrect! correct!
Fig. 4 Fig. 3
29
The Safety Valve
LESER GmbH & Co. KG
E Wendenstr. 133-135

Nennweite EC-type examination No./ Nennweite EC-type examination No./
Type* Type*
NPS DN NPS DN
411 ¾" - 6" 20 - 150 07 202 0111Z0008/0/02 532, 534 ½" - 6" 20 - 150 07 202 0111Z0008/0/15
421 1"- 4" 25 - 100 07 202 0111Z0008/0/03 538 ½" 10 07 202 0111Z0008/0/16
424 – 25 - 200 07 202 0111Z0008/0/04 539 ½" - ¾" 10 - 15 07 202 0111Z0008/0/17
427, 429 ½" - 6" 15 - 150 07 202 0111Z0008/0/05 543, 544 2" - 4" 50 - 100 07 202 0111Z0008/0/18
431, 433 ½" - 6" 15 - 150 07 202 0111Z0008/0/06 546 1" - 4" 25 - 100 07 202 0111Z0008/0/19
440 – 20 - 150 07 202 0111Z0008/0/07 483, 484, 485 1", 2" 25, 40 07 202 0111Z0008/0/20
441, 442, 444 ¾" - 16" 20 - 400 07 202 0111Z0008/0/08-2 437, 438, 439, 481 ½", ¾", Ǫ" – 07 202 0111Z0008/0/21-2
SVL 606 ¾" - 16" 20 - 400 07 202 0111 Z0008/0/08-2 700 – – 07 202 0111Z0008/0/22
447 1" - 4" 25 - 100 07 202 0111Z0008/0/09 522 2" - 4" 50 - 100 07 202 0111Z0008/0/23
448 1" - 4" 25 - 100 07 202 0111Z0008/0/10 450/460 ¾" - 1" 15 - 20 07 202 0111Z0008/0/24
455, 456 1" - 4" 25 - 100 07 202 0111Z0008/0/11 488 1" - 4" 25 - 100 07 202 0111Z0008/0/25-1
457, 458 1" - 6" 25 - 150 07 202 0111Z0008/0/12 SVL 488 1" - 4" 25 - 100 07 202 0111Z0008/0/25-1
459 ½" - 1" 10 - 20 07 202 0111Z0008/0/13 526 1" - 8" 25 - 200 07 202 1111Z0012/2/26
462 ¾" - 1" 15 - 20 07 202 0111Z0008/0/14 486, 586 1" - 3" 25 - 80
Kategorie IV/Category IV

Module/Modul

The signing manufacturer confirms by this declaration that the design, manufacturing and inspection of this pressure
equipment meet the requirements of the Pressure Equipment Directive.
Der unterzeichnende Hersteller bescheinigt hiermit, dass Konstruktion, Herstellung und Prüfung dieses Druckgerätes
den Anforderungen der Druckgeräterichtlinie entsprechen.
LWN 248.13 -06/04
25.11.2004
30
The Safety Valve
according to Pressure Equipment Directive 97/23/EC (PED)
nach Druckgeräterichtlinie 97/23/EG (DGR)
Potentially Explosive Atmospheres 94/9/EC (ATEX)
Explosionsgefährdete Bereiche 94/9/EG (ATEX)
LESER GmbH & Co. KG E
Wendenstr. 133-135

EC-type examination No./ EC-type examination No./
Type* Nennweite Type* Nennweite
NPS DN NPS DN
411 ¾" - 6" 20 - 150 07 202 0111Z0008/0/02 538 ½" 10 07 202 0111Z0008/0/16
421 1"- 4" 25 - 100 07 202 0111Z0008/0/03 539 ½" - ¾" 10 - 15 07 202 0111Z0008/0/17
424 – 25 - 200 07 202 0111Z0008/0/04 543, 544 2" - 4" 50 - 100 07 202 0111Z0008/0/18
427, 429 ½" - 6" 15 - 150 07 202 0111Z0008/0/05 546 1" - 4" 25 - 100 07 202 0111Z0008/0/19
431, 433 ½" - 6" 15 - 150 07 202 0111Z0008/0/06 483, 484, 485 1", 2" 25, 40 07 202 0111Z0008/0/20
440 – 20 - 150 07 202 0111Z0008/0/07 437, 438, 439, 481 ½", ¾", Ǫ" – 07 202 0111Z0008/0/21-1
441, 442, 444 ¾" - 16" 20 - 400 07 202 0111Z0008/0/08-2 700 - - 07 202 0111Z0008/0/22
455, 456 1" - 4" 25 - 100 07 202 0111Z0008/0/11 522 2" - 4" 50 - 100 07 202 0111Z0008/0/23
457, 458 1" - 6" 25 - 150 07 202 0111Z0008/0/12 450/460 ¾" - 1" 15 - 20 07 202 0111Z0008/0/24
459 ½" - 1" 10 - 20 07 202 0111Z0008/0/13 488 1" - 4" 25 - 100 07 202 0111Z0008/0/25
462 ¾" - 1" 15 - 20 07 202 0111Z0008/0/14 526 1" - 8" 25 - 200 07 202 1111Z0012/2/26
532, 534 ½" - 6" 20 - 150 07 202 0111Z0008/0/15
Category IV/Kategorie IV (PED/DGR)


Module/Modul

Group II, Category 1, 2 and 3/Gruppe II, Kategorie 1, 2 und 3 (ATEX)

The signing manufacturer declares that in compliance with the Directive 94/9/EC, the products detailed above are suitable
for use as equipment group II categories 1, 2 and 3 and have been manufactured acc. to Annex VIII "Internal control of
production".
Der unterzeichnende Hersteller bestätigt, dass in Übereinstimmung mit der Richtlinie 94/9/EG, die oben aufgeführten
Produkte für die Verwendung als Geräte der Gruppe II, Kategorien 1, 2 und 3 geeignet sind und entsprechend
Anhang VIII "Interne Fertigungskontrolle" hergestellt wurden.
LWN 248.21 -06/2004
June 30, 2004

Date/Datum Manufacturer stamp/Herstellerstempel Authorized subscriber/Authorisierter Unterzeichner
31
The Safety Valve
E LESER GmbH & Co. KG

Wendenstr. 133-135
Applied category in Conformity assessment

Nominal Description of
acc. to article 3 and procedures according to CE-
pipe pressure
Material/ annex II/ article 10/ marking/
Type* size/ equipment/
Werkstoff Angewandte Kategorie Angewandte Konformitäts- CE-Kenn-
Nenn- Benennung des
nach Artikel 3 und bewertungsverfahren nach zeichnung
weite DN Druckgerätes
Anhang II Artikel 10
Art. 3 Par. 3 Not necessary No
0.6025 15-50
GG-25/
GJL-250 Kat. I Yes
65-100 A
Pressure Reducer Cat. I Ja
612
Druckminderer Art. 3 Par. 3 Not necessary No
1.0619 15-32
GS-C 25/
GP 240 GH Kat. I Yes
40-100 A
Cat. I Ja

Module/Modul
D1 Production quality assurance/Qualitätssicherung Produktion 07 202 0111Z0008/0/01-2
Certificate number of module D1/Zertifikatsnummer Modul D1

Identification number: 0045, Große Bahnstr. 31, 22525 Hamburg/Germany
The signing manufacturer confirms by this declaration that the design, manufacturing and inspection of this
pressure equipment meet the requirements of the Pressure Equipment Directive.
Der unterzeichnende Hersteller bescheinigt hiermit, dass Konstruktion, Herstellung und Prüfung dieses
Druckgerätes den Anforderungen der Druckgeräterichtlinie entsprechen.
DIN EN 1503-1, DIN EN 1503-3, DIN EN 10213-1, DIN EN 10213-2

DIN 3840, DIN 1691, DIN EN 1561

LWN 248.14 -06/04
30.06.2004
32
10. Messtechnik
10. Measurement

Commission-N°:
7001021687
Factory-N°:
4020005 Project:
TIMOR 2
Drawing-N°:
BB2285B
Baujahr: Pos.-Nr.:

14 Pressure Measurement
14,1 12MAM60CP510 1 WIKA 233.50.100 1/2" NPT Body: 316L -- pressure gauge
Commission-No.:
Customer:

Factory-No.:
4020005 TIMOR 2
Project:
Drawing-No.:
67-3266 BB285B
Project-No.:
Baujahr: Pos.-Nr.:
2021 --
Pos.-No.:
Pos. 14 Pressure
12MAM60CP510
Bourdon tube pressure gauge, stainless steel
For the process industry, standard version
Models 232.50, 233.50, NS 63 [2 ½"], 100 [4"] and 160 [6"]
WIKA data sheet PM 02.02
for further approvals

see page 5
Applications
■ For gaseous and liquid aggressive media that are
not highly viscous or crystallising, also in aggressive
environments
■ Chemical and petrochemical industries, oil and gas indus-
try, power engineering and also water and wastewater
technology
■ Machine building and general plant construction
Special features
■ Excellent load-cycle stability and shock resistance
■ With case filling (model 233.50) for applications with high
dynamic pressure loads and vibrations
■ Completely from stainless steel
■ Scale ranges from 0 … 0.6 to 0 … 1,600 bar
[0 ... 10 to 0 ... 20,000 psi] Bourdon tube pressure gauge, model 232.50,
NS 100 [4"]
Description
This high-quality Bourdon tube pressure gauge has been WIKA manufactures and qualifies the pressure gauge
designed especially for the process industry. in accordance with the standards EN 837-1 and
ASME B40.100. This instrument has as safety function a
The use of high-quality stainless steel materials and the blow-out device with blow-out plug on the back of the case. In
robust design are geared to applications in the chemical the event of a failure, overpressure can escape there.
and process engineering industries. Thus the instrument is
suitable for liquid and gaseous media, also in aggressive The model 233.50 with liquid-filled case is suitable for high
environments. dynamic pressure loads and vibrations.
Scale ranges of 0 … 0.6 to 0 … 1,600 bar [0 ... 10 to

0 ... 20,000 psi] ensure the measuring ranges required for a
wide variety of applications.
Data sheets showing similar products:

Stainless steel, safety version; model 232.30; see data sheet PM 02.04
Bourdon tube pressure gauge with switch contacts; models PGS23.100 and PGS23.160; see data sheet PV 22.02
Pressure gauge per EN 837-1 with mounted diaphragm seal; model DSS27M; see data sheet DS 95.12
Specifications
Basic information
■ ASME B40.100
For information on the “Selection, installation, handling and operation of pressure

gauges”, see Technical information IN 00.05.
Nominal size (NS) ■ Ø 63 mm [2 ½"]
■ Ø 100 mm [4"]
■ Ø 160 mm [6"]
Window Laminated safety glass (NS 63 [2 ½"]: Polycarbonate)

Case
Design Safety level “S1” per EN 837-1
With blow-out device at case circumference, 12 o‘clock (NS 63 [2 ½"]) and on the
back of the case (NS 100 [4"] and 160 [6"])
Scale ranges ≤ 0 ... 16 bar [≤ 0 ... 300 psi] with compensating valve to vent and
reseal case
Material ■ Stainless steel 1.4301 (304)
■ Stainless steel 1.4571 (316 Ti)
Ring Bayonet ring, stainless steel

Mounting ■ Without
■ Panel mounting flange, stainless steel
■ Panel mounting flange, polished stainless steel
■ Triangular profile ring, stainless steel polished with mounting bracket
■ Surface mounting flange, stainless steel
Case filling (model 233.50) ■ Without
■ Glycerine
■ Glycerine-water mixture for NS 100 [4“] and 160 [6“] with scale range
≤ 0 ... 2.5 bar [≤ 0 ... 40 psi] or for NS 63 [2 ½“] with scale range ≤ 0 ... 4 bar
[≤ 0 ... 60 psi]
■ Silicone oil
Movement ■ Stainless steel

■ everlast® design
Measuring element
Type of measuring element Bourdon tube, C-type or helical type
Material ■ Stainless steel 1.4404 (316L)
Leak tightness ■ Helium tested, leakage rate: < 5∙10-3 mbar l/s
■ Helium tested, leakage rate: < 1∙10-6 mbar l/s
Accuracy specifications
Accuracy class
NS 63 [2 ½"] ■ EN 837-1 Class 1.6
■ ASME B40.100 ±2 ½ % of measuring span (grade A)
NS 100 [4"], 160 [6"] ■ EN 837-1 Class 1,0
■ ASME B40.100 ±1.0 % of measuring span (grade 1A)
Temperature error On deviation from the reference conditions at the measuring system:
≤ ±0.4 % per 10 °C [≤ ±0.4 % per 18 °F] of full scale value
Reference conditions
Ambient temperature +20 °C [68 °F]

Scale ranges
Scale range Scale range

bar kg/cm2 psi psi
0 ... 0.6 1) 0 ... 0.6 1) 0 ... 10 1) 0 ... 1,000
0 ... 1 0 ... 1 0 ... 15 0 ... 1,500
0 ... 1.6 0 ... 1.6 0 ... 30 0 ... 2,000
0 ... 2.5 0 ... 2.5 0 ... 60 0 ... 3,000
0 ... 4 0 ... 4 0 ... 100 0 ... 4,000
0 ... 6 0 ... 6 0 ... 160 0 ... 5,000
0 ... 10 0 ... 10 0 ... 200 0 ... 6,000
0 ... 16 0 ... 16 0 ... 300 0 ... 7,500
0 ... 25 0 ... 25 0 ... 400 0 ... 10,000
0 ... 40 0 ... 40 0 ... 600 0 ... 20,000
0 ... 60 0 ... 60 0 ... 800
0 ... 100 0 ... 100
0 ... 160 0 ... 160
0 ... 250 0 ... 250 Vacuum and +/- scale ranges
0 ... 400 0 ... 400 Scale range
0 ... 600 0 ... 600 bar MPa
0 ... 1,000 0 ... 1,000 -0.6 ... 0 1) -0.06 ... 0 1)
0 ... 1,600 0 ... 1,600 -1 ... 0 -0.1 ... 0
kPa MPa -1 ... +0.6 -0.1 ... +0.06
0 ... 60 1) 0 ... 0.06 1) -1 ... +1.5 -0.1 ... +0.15
0 ... 100 0 ... 0.1 -1 ... +3 -0.1 ... +0.3
0 ... 160 0 ... 0.16 -1 ... +5 -0.1 ... +0.5
0 ... 250 0 ... 0.25 -1 ... +9 -0.1 ... +0.9
0 ... 400 0 ... 0.4 -1 ... +15 -0.1 ... +1.5
0 ... 600 0 ... 0.6 -1 ... +24 -0.1 ... +2.4
0 ... 1,000 0 ... 1 kPa psi
0 ... 1,600 0 ... 1.6 -60 ... 0 1) -30 inHg ... 0
0 ... 250 0 ... 2.5 -100 ... 0 -30 inHg ... +15
0 ... 400 0 ... 4 -100 ... +60 -30 inHg ... +30
0 ... 600 0 ... 6 -100 ... +150 -30 inHg ... +60
0 ... 1,000 0 ... 10 -100 ... +300 -30 inHg ... +100
0 ... 1,600 0 ... 16 -100 ... +500 -30 inHg ... +160
0 ... 2,500 0 ... 25 -100 ... +900 -30 inHg ... +200
0 ... 4,000 0 ... 40 -100 ... +1,500 -30 inHg ... +300
0 ... 6,000 0 ... 60 -100 ... +2,400
0 ... 10,000 0 ... 100
0 ... 16,000 0 ... 160
1) Not available for NS 63 [2 ½"]

Special scale ranges Other scale ranges on request
Unit ■ bar
■ psi
■ kg/cm²
■ kPa
■ MPa

Increased overload safety ■ Without
■ 2 times
■ 3 times
■ 4 times
■ 5 times
The possibility of selection depends on scale range and nominal size
Vacuum resistance ■ Without
■ Vacuum-resistant to -1 bar
Dial
Scale colour Black
Material Aluminium
Special scale ■ Without
■ With temperature scale for refrigerant, e.g. for NH3: R 717
Other scales or customer-specific dials, e.g. with red mark, circular arcs or circular
sectors, on request
Pointer
Instrument pointer Aluminium, black
Mark pointer/drag pointer ■ Without
■ Red mark pointer on dial, fixed
■ Red mark pointer on window, adjustable
■ Mark pointer on bayonet ring, adjustable
■ Red drag pointer on window, adjustable
Pointer stop pin ■ Without
■ At the zero point (only for NS 63 [2 ½"])
■ At 6 o‘clock (only for NS 100 [4"], 160 [6"])
Process connections
■ ISO 7
■ ANSI/B1.20.1
Size
EN 837-1 ■ G ⅛ B, male thread
■ G ¼ B, male thread
■ G ½ B, male thread
ISO 7 ■ R ¼, male thread
■ R ½, male thread
ANSI/B1.20.1 ■ ¼ NPT, male thread

■ ½ NPT, male thread
Restrictor ■ Without
Materials (wetted)
Process connection ■ NS 100 [4"], 160 [6"]: Stainless steel 1.4404 (316L)
■ NS 63 [2 ½"]: Stainless steel 1.4571 (316 Ti)
Bourdon tube ■ Stainless steel 1.4404 (316L)

Other process connections on request

Operating conditions
Medium temperature
Unfilled instruments -40 ... +200 °C [-40 ... +392 °F]
Instruments with silicone oil filling -40 ... +100 °C [-40 ... +212 °F]
Ambient temperature
Unfilled instruments or with silicone oil filling -40 ... +60 °C [-40 ... +140 °F]
Pressure limitation
NS 63 [2 ½"] Steady 3/4 x full scale value
Fluctuating 2/3 x full scale value
Short time Full scale value
NS 100 [4"], 160 [6"] Steady Full scale value
Fluctuating 0.9 x full scale value
Short time 1.3 x full scale value
Ingress protection per IEC/EN 60529 ■ IP65
■ IP66 (only selectable for scale ranges from 0 ... 20 bar [ 0 ... 400 psi])

Approvals
Approvals included in the scope of delivery

Pressure equipment directive
PS > 200 bar, module A, pressure accessory
- CRN Canada
Safety (e.g. electr. safety, overpressure, ...)
For scale ranges ≤ 1,000 bar
Optional approvals
ATEX directive
Hazardous areas
- Ex h Gas II 2G Ex h IIC T6 ... T1 Gb X
Dust II 2D Ex h IIIC T85°C ... T450°C Db X
EAC Eurasian Economic Community

Hazardous areas
GOST Russia
KazInMetr Kazakhstan
- MTSCHS Kazakhstan
Permission for commissioning
BelGIM Belarus
UkrSEPRO Ukraine
Uzstandard Uzbekistan
- CPA China
DNV GL International
Ships, shipbuilding (e.g. offshore)
Certificates (option)
Certificates
Certificates ■ 2.2 test report per EN 10204 (e.g. state-of-the-art manufacturing, indication accuracy)
■ 3.1 inspection certificate per EN 10204 (e.g. material proof for wetted metal parts, indication accuracy)
■ PCA calibration certificate, traceable and accredited in accordance with ISO/IEC 17025
■ Calibration certificate by the national accreditation body, traceable and accredited in accordance with
ISO/IEC 17025 on request
Recommended 1 year (dependent on conditions of use)
recalibration interval
→ Approvals and certificates, see website

Lower mount (radial)
b
j
Øk
ØD1
ØD2 NS Weight
h
SW Model 232.50 Model 233.50
14311051.01
G G
ISO ANSI a 160 [6"] approx. 1.1 kg [2.43 lbs] approx. 2.0 kg [4.41 lbs]

63 [2 ½"] G¼B 54 [2.13] 9.5 [0.37] 33 [1.30] 63 [2.48] 62 [2.44] 6 [0.24] 10 [0.39] 15 [0.59] 14 [0.55]
G⅛B 51 [2.01]
M12 x 1.5 54 [2.13]
100 [4"] G¼B 80 [3.15] 15.5 [0.61] 49.5 [1.95] 101 [3.98] 99 [3.90] 6.5 [0.26] 14.5 [0.57] 22.5 [0.89] 22 [0.87]
G½B 87 [3.43]
M12 x 1.5 80 [3.15]
M20 x 1.5 87 [3.43]
160 [6"] G¼B 111 [4.37] 15.5 [0.61] 49.5 [1.95] 1) 161 [6.34] 159 [6.26] 6.5 [0.26] 14.5 [0.57] 22.5 [0.89] 22 [0.87]
G½B 118 [4.65]
M12 x 1.5 111 [4.37]
M20 x 1.5 118 [4.65]

63 [2 ½"] R¼ 54 [2.13] 9.5 [0.37] 33 [1.30] 63 [2.48] 62 [2.44] 6 [0.24] 10 [0.39] 15 [0.59] 14 [0.55]
100 [4"] R¼ 80 [3.15] 15.5 [0.61] 49.5 [1.95] 101 [3.98] 99 [3.90] 6.5 [0.26] 14.5 [0.57] 22.5 [0.89] 22 [0.87]
R½ 86 [3.39]
160 [6"] R¼ 111 [4.37] 15.5 [0.61] 49.5 [1.95] 1) 161 [6.34] 159 [6.26] 6.5 [0.26] 14.5 [0.57] 22.5 [0.89] 22 [0.87]
R½ 117 [4.60]

63 [2 ½"] ¼ NPT 54 [2.13] 9.5 [0.37] 33 [1.30] 63 [2.48] 62 [2.44] 6 [0.24] 10 [0.39] 15 [0.59] 14 [0.55]
⅛ NPT 51 [2.01]
100 [4"] ¼ NPT 80 [3.15] 15.5 [0.61] 49.5 [1.95] 101 [3.98] 99 [3.90] 6.5 [0.26] 14.5 [0.57] 22.5 [0.89] 22 [0.87]
½ NPT 86 [3.39]
160 [6"] ¼ NPT 111 [4.37] 15.5 [0.61] 49.5 [1.95] 1) 161 [6.34] 159 [6.26] 6.5 [0.26] 14.5 [0.57] 22.5 [0.89] 22 [0.87]
½ NPT 117 [4.60]

Lower back mount
b
j
i
Øk
ØD1
SW
ØD2
e
ISO
G
NS Weight
ANSI

G
1431111.01
h1 100 [4"] approx. 0.6 kg [1.32 lbs] approx. 0.9 kg [1.98 lbs]

63 [2 ½"] G¼B 57 [2.24] 33 [1.30] 63 [2.48] 62 [2.44] 18.5 [0.73] 6 [0.24] 10 [0.39] 15 [0.59] 14 [0.55]
G⅛B 54 [2.13]
M12 x 1.5 57 [2.24]
100 [4"] G¼B 76 [2.99] 49.5 [1.95] 101 [3.98] 99 [3.90] 30 [1.18] 6.5 [0.26] 14.5 [0.57] 22.5 [0.89] 22 [0.87]
G½B 83 [3.27]
M12 x 1.5 76 [2.99]
M20 x 1.5 83 [3.27]
160 [6"] G¼B 76 [2.99] 2) 49.5 [1.95] 1) 161 [6.34] 159 [6.26] 50 [1.97] 6.5 [0.26] 14.5 [0.57] 22.5 [0.89] 22 [0.87]
G½B 83 [3.27] 2)
M12 x 1.5 76 [2.99] 2)
M20 x 1.5 83 [3.27] 2)

63 [2 ½"] R¼ 57 [2.24] 33 [1.30] 63 [2.48] 62 [2.44] 18.5 [0.73] 6 [0.24] 10 [0.39] 15 [0.59] 14 [0.55]
100 [4"] R¼ 76 [2.99] 49.5 [1.95] 101 [3.98] 99 [3.90] 30 [1.181] 6.5 [0.26] 14.5 [0.57] 22.5 [0.89] 22 [0.87]
R½ 82 [3.23]
160 [6"] R¼ 76 [2.99] 2) 49.5 [1.95] 1) 161 [6.34] 159 [6.26] 50 [1.97] 6.5 [0.26] 14.5 [0.57] 22.5 [0.89] 22 [0.87]
R½ 82 [3.23] 2)

63 [2 ½"] ¼ NPT 54 [2.13] 33 [1.30] 63 [2.48] 62 [2.44] 50 [1.97] 6 [0.24] 10 [0.39] 15 [0.59] 14 [0.55]
⅛ NPT 51 [2.01]
100 [4"] ¼ NPT 80 [3.15] 49.5 [1.95] 101 [3.98] 99 [3.90] 50 [1.97] 6.5 [0.26] 14.5 [0.57] 22.5 [0.89] 22 [0.87]
½ NPT 86 [3.39]
160 [6"] ¼ NPT 76 [2.99] 2) 49.5 [1.95] 1) 161 [6.34] 159 [6.26] 50 [1.97] 6.5 [0.26] 14.5 [0.57] 22.5 [0.89] 22 [0.87]
½ NPT 82 [3.23] 2)
2) Plus 16 mm [0.630 in] with scale ranges ≥ 0 ... 100 bar [≥ 0 ... 1,500 psi]

NS 63 [2 ½"], centre back mount
b
≤ 16 bar [≤ 300 psi] with vent valve j
> 16 bar [> 300 psi] without vent valve Øk
i
SW
ISO
ØD1
ØD2
G
ANSI
G
h1
NS Weight
14112247.01
63 [2 ½“] approx. 0.16 kg [0.35 lbs] approx. 0.20 kg [0.44 lbs]

63 [2 ½"] G¼B 57 [2.24] 33 [1.30] 63 [2.48] 62 [2.44] 6 [0.24] 10 [0.39] 15 [0.59] 14 [0.55]
G⅛B 54 [2.13]
M12 x 1.5 57 [2.24]

63 [2 ½"] R¼ 57 [2.24] 33 [1.30] 63 [2.48] 62 [2.44] 6 [0.24] 10 [0.39] 15 [0.59] 14 [0.55]

63 [2 ½"] ¼ NPT 57 [2.24] 33 [1.30] 63 [2.48] 62 [2.44] 6 [0.24] 10 [0.39] 15 [0.59] 14 [0.55]
⅛ NPT 54 [2.13]

Accessories
Panel mounting flange Surface mounting flange
Ød2 Ød2
Ød1 Ød1
°
°
120
120
120
120
°
°
Ød3
Ød3
Recommended panel cutout d1 d2 d3
63 [2 ½"] ∅ 67 ±0.3 / ∅ 2.6 [∅ 2.64 ±0.01 / ∅ 0.10] 75 [2.95] 85 [3.35] 3.6 [0.14]
100 [4"] ∅ 104 ±0.5 / ∅ 4.1 [∅ 4.04 ±0.02 / ∅ 0.16] 117 [4.61] 132 [5.20] 4.8 [0.19]
160 [6"] ∅ 164 ±0.5 / ∅ 6.5 [∅ 6.46 ±0.02 / ∅ 0.26] 178 [7.01] 196 [7.71] 5.8 [0.23]
Triangular profile ring

max. 9
Recommended panel d4
Ød4
cutout
63 [2 ½"] ∅ 64.5 ±0.5 / ∅ 2.5 ≤ 69 [2.72]
[∅ 2.54 ±0.02 / ∅ 0.01]
NS 100 [4"] ∅ 102 ±1.0 / ∅ 4.0 ≤ 108 [4.25]
[∅ 4.02 ±0.04 / ∅ 0.16]
NS 160 [6"] ∅ 162.6 ±1.0 / ∅ 6.4 ≤ 168 [6.61]
[∅ 6.40 ±0.04 / ∅ 0.25]

Accessories and spare parts
Model Description
910.17 Sealings
910.15 Syphons
910.13 Overpressure protector

IV10, IV11 Needle valve and multiport valve

IV20, IV21 Block-and-bleed valve

IVM Monoflange, process and instrument version

BV Ball valve, process and instrument version

IBF2, IBF3 Monoblock with flange connection

Ordering information
Model / Nominal size / Scale range / Process connection / Connection location / Options
© 02/1995 WIKA Alexander Wiegand SE & Co. KG, all rights reserved.
The specifications given in this document represent the state of engineering at the time of publishing.
We reserve the right to make modifications to the specifications and materials.
01/2021 EN
WIKA Alexander Wiegand SE & Co. KG

Alexander-Wiegand-Straße 30
63911 Klingenberg/Germany
Tel. +49 9372 132-0
Fax +49 9372 132-406
[email protected]
www.wika.de
Operating 1. Safety gauge, it must be protected against being blocked
instructions EN WARNING!
by debris and dirt. With safety pressure gauges
(see k) there must be a free space of > 15 mm
Before installation, commissioning and
behind the blow-out back.
operation, ensure that the appropriate
After installation, open the vent valve (if available)
Pressure gauges pressure gauge has been selected in
or set from CLOSE to OPEN. With
terms of measuring range, design and
models 4 and 7, do not open the
suitable wetted material (corrosion) for the specific
flange mounting screws. The version
measuring conditions. In order to guarantee the
of the vent valve depends on the
measurement accuracy and long-term stability
Examples: model and can deviate from the above illustration!
specified, the corresponding load limits must be
observed. Requirements for the installation point
Only qualified persons authorised by the plant If the line to the measuring instrument is not
manager are permitted to install, maintain and adequately stable, a measuring instrument holder
service the pressure gauges. should be used for fastening (and possibly via a
Model 732.14, flexible capillary). If vibrations cannot be avoided
For hazardous media such as oxygen, acetylene,
overpressure safety by means of suitable installation, instruments
flammable or toxic gases or liquids, and refrigera-
up to 400 bar with liquid filling should be used. The instruments
tion plants, compressors, etc., in addition to all
Model 432.56, should be protected against coarse dirt and wide
standard regulations, the appropriate existing
overpressure safety fluctuations in ambient temperature.
codes or regulations must also be followed.
up to 100 bar Note for model 732.14, for front bezel mounting:
From pressure gauges which do not correspond The front bezel serves as centring and as the
Model 213.40 to a safety version per EN 837 highly pressurised aperture in the mounting panel. Securing and thus
media might leak out through the possibly burst- the weight-bearing must be made via the pressure
ing window in case of a component failure. For connection piping.
gaseous media and working pressures > 25 bar a
pressure gauge with safety version S3 is recom- 3. Permissible ambient and operating
mended per EN 837-2. temperatures
After an external fire, pressure media can leak out, When mounting the pressure gauge it must be
Notes per current pressure equipment directive particularly at soft solder joints. All instruments ensured that, taking into consideration the influ-
The pressure gauges are defined as “pressure must be checked and, if necessary, replaced ence of convection and heat radiation, no deviation
accessories” before recommissioning the plant. above or below the permissible temperature limits
The volume of the “pressure-bearing housings” of can occur. Observe the influence of temperature
Non-observance of the respective regulations on the indication accuracy!
WIKA pressure gauges is < 0.1 L
can cause serious injuries and/or damage to the
The pressure gauges carry CE marking for fluid
equipment. 4. Storage
group 1 per annex II, diagram 1 when their permis-
sible working pressure is > 200 bar 2. Mechanical connection To protect the pressure gauges from mechanical
damage keep them in the original packaging until
Instruments that do not carry the mark are manufactured In accordance with the general technical regula- installation.
per article 4, paragraph 3 “sound engineering practice”. tions for pressure gauges (e.g. EN 837-2). When Protect the measuring instruments from humidity
screwing the instruments in, the force required to and dust.
Applicable standards (depending on model) do this must not be applied through the case, but Storage temperature range: -40 ... +70 °C
EN 837-1 Bourdon tube pressure gauges, dimensions, only through the spanner flats provided for this Storage temperature range model
metrology, requirements and testing purpose, and using a suitable tool. PG23LT: -70 ... +70 °C
EN 837-2 Selection and installation recommendations For parallel threads, use flat gaskets, lens-type
for pressure gauges sealing rings or WIKA profile sealings at the 5. Maintenance and repairs
EN 837-3 Diaphragm and capsule pressure gauges, The pressure gauges are maintenance-free.
dimensions, metrology, requirements and Regular checks should be carried out to ensure
testing Installation with the measurement accuracy. Checks or recalibra-
Specifications: See data sheet at www.wika.de open-ended tions must only be carried out by qualified skilled
spanner personnel with the appropriate equipment. When
Subject to technical modifications. dismounting, close the vent valve (if available).
© WIKA Alexander Wiegand SE & Co. KG 2009 Sealing of the pressure gauge connections
WARNING! Residual media in
Sealing in dismounted pressure gauges can
Spanner flats the thread result in a risk to persons, the environ-
 ment and equipment. Take sufficient
Sealing face  precautionary measures.
sealing face . With tapered threads (e.g. NPT
WIKA Alexander Wiegand SE & Co. KG threads), sealing is made in the threads  using
Alexander-Wiegand-Straße 30 additional sealing materials, e.g. PTFE tape
2408976.06 12/2016
63911 Klingenberg/Germany (EN 837-2).

Tel. +49 9372 132-0 The torque depends on the sealing used. In order
Fax +49 9372 132-406 to orientate the measuring instrument so that it
[email protected] can be read as well as possible, a connection with
www.wika.de clamp socket or union nut should be used.
When a blow-out device is fitted to a pressure

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List of KKS

KKS Component Type Manufacturer Supplier

Herrfurthstraße 9 • D - 06217 Merseburg

Kommissions-Nr.: Auftraggeber: Siemens Energy Global

4 SECTION A-A DESIGNER: ANA Prozesstechnik GmbH

2 11 MAM65AA520 11 MAM65AA510 2 AEL-Fabrik-Nr. Baujahr

2 Firmenschild Kondensator / name plate condenser Korrosionszuschlag

06217 Merseburg Andere Prüfungen siehe Schweiß- und

min./max. zulässige Temperatur

Test pressure 3,0 bar g 36,5 bar g Insulation warm/cold

Anschlussrohrleitung muss unmittelbar

Die Armatureneinheit ist während des Transports demontiert.

The valve unit is seperate during transport. 2 STUTZENTABELLE / TABLE OF NOZZLES

Die Rohrleitung ist während des Transports demontiert. Kondensataustritt ASME

M 147 [153] N1;N2 1,35 1,15 1 0,3 0,6 0,465

15 1 Traggestell support -- 1.0038

150 90 4 measures in [...] are actual size

P Absperrklappe mit 90 150

9 3 Rasthebel butterfly 3''

C 2020 by ANA Prozesstechnik GmbH

0 27.08.2020 SMI ZQA ARI Erstausgabe / first issue

Q 6 Kondensatablaufleitung 70 Zust. Datum erstellt geprüft genehmigt Bemerkungen

2. Leistungsdaten Kondensator /Performance data condenser

3. Design and principle of operation

Related P&ID Gland steam system 0-06420-BB2284A-02

4. (Un-) Installation Advices

6.1. Before Start-up

 Set the module up.

• Inspect all transfer points for proper connection and hook-up.

 discontinue the cooling water supply.

MAM65AA010 MAM65AN110 MAM65AA510 3"

P&I diagram condensate system

MAW10CT201 MAW10CP201 PS = 27.05 barg

BR010 BR010 MAM60 01 0-06420-BB2284A-10

r R Turbine Control System (TCS)

f f ü Local control system (black box)

Max. OPERATING DATA

CONSORTIUM DWG. NO. :

Code Word: SULUT / TIMOR

Project No.: BB002284 / BB002285

G 2021-02-15 Koppeel Guretzka Guretzka see Rev.-Index

Timor Sulut Rev.

Date Name Scale

SIEMENS No. BB002285A BB002285B BB002284A BB002284B A0 0-06420-BB2284A-02 G de en 1/1

Protection class: Restricted © Siemens Energy, 2020

4. Installation- and safety instructions

Operation: Before starting a tightness check must be carried out!

Kommissions-Nr.: Auftraggeber: Siemens Energy Global

Storage: The storage have to occur in a unfired and dry depot.

Kommissions-Nr.: Auftraggeber: Siemens Energy Global

Komponente: Leckdampf-Kondensator 11MAM60AC010

Zeichnung 65-2432X - Rev. 3

A DESIGNER: ANA Prozesstechnik GmbH A

toxisch / brennbar / explosiv NEIN / NO NEIN / NO

F220-3511-002 AEL APPARATEBAU GmbH

C 2020 by ANA Prozesstechnik GmbH

vapor outlet geltende Normen 4

min./max. zulässiger Druck

- Montageanleitung / installation manual

Customer: ANA Prozesstechnik GmbH