PA 46 PA 47 MPA 46 MPA 47: GESTRA Steam Systems

GESTRA Steam Systems
PA 46 EN
English
PA 47
MPA 46
MPA 47
Installation Instructions 81844701
RapidAction Intermittent Valve for Removing Boiler Sludge
PA 46, PA 47, MPA 46, MPA 47

Contents
Page
Important Notes
Usage for the intended purpose...............................................................................................................4
Safety note..............................................................................................................................................4
Danger....................................................................................................................................................4
Attention..................................................................................................................................................4
PED (Pressure Equipment Directive).........................................................................................................5
ATEX (Atmosphre Explosible)..................................................................................................................5
Explanatory Notes
Scope of supply.......................................................................................................................................6
Description..............................................................................................................................................7
Function..................................................................................................................................................7
Technical Data
Name plate / marking..............................................................................................................................8
Dimensions PA 46, PA 47.........................................................................................................................9
Dimensions MPA 46, MPA 47.................................................................................................................10
End dimensions of flanges (extract).......................................................................................................11
Dimensions of butt-weld ends (extract)..................................................................................................12
Dimensions of socket-weld ends (extract)..............................................................................................12
Pressure & temperature ratings / Connections.......................................................................................13
Materials...............................................................................................................................................14
Corrosion resistance..............................................................................................................................14
Sizing....................................................................................................................................................14
Capacity chart PA 46, PA 47, MPA 46, MPA 47.......................................................................................15
Control pressure chart MPA 46, MPA 47.................................................................................................16
Design
PA 46, PA 47..........................................................................................................................................17
MPA 46, MPA 47....................................................................................................................................18
Key........................................................................................................................................................19
Installation
PA 46, PA 47, MPA 46, MPA 47..............................................................................................................20
Attention................................................................................................................................................20
Flanged design......................................................................................................................................20
Socket-weld design...............................................................................................................................20
Butt-weld design...................................................................................................................................21
Heat treatment of welds........................................................................................................................21
Mounting hand lever PA 46, PA 47.........................................................................................................21
Changing position of hand lever.............................................................................................................21
Changing the operating side of the intermittent blowdown valve PA 46 / PA 47......................................22
Changing the operating side of the intermittent blowdown valve MPA 46 / MPA 47................................23
Commissioning
Danger..................................................................................................................................................24
PA 46, PA 47, MPA 46, MPA 47 .............................................................................................................24

Contents - continued -
Page
Operation
Danger..................................................................................................................................................25
Intermittent boiler blowdown.................................................................................................................25
Duration and frequency of intermittent boiler blowdown........................................................................25
Emergency operation MPA 46, MPA 47

Danger..................................................................................................................................................26
Fitting hand lever for emergency operation............................................................................................26
Maintenance
Retightening stuffing box.......................................................................................................................26
Attention................................................................................................................................................26
Replacing stuffing box PA 46, PA 47.......................................................................................................27
Replacing stuffing box, valve seat and valve plug PA 46, PA 47..............................................................28
Replacing stuffing box MPA 46, MPA 47.................................................................................................29
Replacing stuffing box, valve seat and valve plug MPA 46, MPA 47........................................................30
Replacing control membrane in diaphragm actuator MPA 46, MPA 47....................................................31
Attention................................................................................................................................................31
Torques required for tightening..............................................................................................................32
Tools......................................................................................................................................................32
Single parts of stuffing box, valve plug, valve seat..................................................................................33
Mounting / removing valve seat.............................................................................................................34
Mounting / removing control membrane................................................................................................35
Key........................................................................................................................................................36
Retrofitting
Danger..................................................................................................................................................36
Mounting diaphragm actuator................................................................................................................37
Mounting an existing MPA 26, MPA 27 diaphragm actuator....................................................................37
Mounting the forkhead (hand lever for emergency operation).................................................................38
Mounting the limit switch (proximity switch).................................................................................... 38-39
Tools......................................................................................................................................................40
Torques required for tightening..............................................................................................................40
Spare Parts
Spare parts list......................................................................................................................................41
Parts for retrofitting

List of parts for retrofitting.....................................................................................................................42
Decommissioning
Danger..................................................................................................................................................42
Disposal................................................................................................................................................42
Annex
Declaration of Conformity......................................................................................................................43

Important Notes
Usage for the intended purpose
PA 46, PA 47, MPA 46, MPA 47:

Use the rapid-action intermittent valves*) only for removing boiler water containing accumulated
non-metallic sediments from steam boilers within the admissible pressure und temperature ratings.
Use only compressed air (at room temperature) or pressurized water (at room temperature) as control
fluid for the GESTRA diaphragm actuator in accordance with the specified pressure/temperature
ratings.
*) Please note:
In British English an intermittent valve for removing boiler sludge is referred to as (intermittent)
bottom blowdown valve.
In American English the term (intermittently operating) blowoff valve is used, but only in
conjunction with a slow-opening valve (ASME code).
Safety Note
The equipment must only be installed and commissioned by qualified and competent staff.
Retrofitting and maintenance work must only be performed by qualified staff who through adequate
training have achieved a recognised level of competence.
Danger
The valve is under pressure during operation.

When loosening flanged connections, sealing plugs or stuffing boxes, hot water and
steam may escape.
The valve becomes hot during operation.
This presents the risk of severe burns to hands and arms.
Before servicing or retrofitting the valve or loosening flanges, stuffing box connections
or sealing plugs make sure that all connected lines are depressurised (0 bar) and cooled
down to room temperature (20 C).
Sharp edges on internals present a danger of cuts to hands. Always wear industrial
gloves when replacing the packing, valve seat or valve plug.
During operation moving internals can pinch ones hands or fingers. Do not touch
moving parts! The intermittent valves for removing boiler sludge MPA 46, MPA 47 are
remote controlled and can open and close very abruptly.
Attention
The name plate specifies the technical features of the equipment. Note that any piece of
equipment without its specific name plate must neither be commissioned nor operated.

Important Notes continued
PED (Pressure Equipment Directive)
The equipment meets the requirements of the Pressure Equipment Directive 97/23/EC.
Application in fluids of group 2. With CE marking, except equipment according to section 3.3.
ATEX (Atmosphre Explosible)
The valves PA 46, PA 47, MPA 46, MPA 47 can be used in potentially explosive areas, provided that the
following notes are observed:
The operating fluid must not generate excessively high temperatures. Electrostatic charges that may
be generated during operation must be discharged. Make sure that the stuffing box is tight and that
the valve spindle can run smoothly. The equipment can be used in Ex zones 1, 2, 21, 22 (1999/92/EC)
II 2 G/D c X.
For more information refer to our ATEX Declaration of Conformity.

Explanatory Notes
Scope of supply
PA 46
1 Intermittent valve for removing boiler sludge PA 46
1 Hand lever
1 Installation manual
PA 47
1 Intermittent valve for removing boiler sludge PA 47
1 Hand lever
MPA 46
1 Intermittent valve for removing boiler sludge MPA 46
MPA 47
1 Intermittent valve for removing boiler sludge MPA 47
Retrofitting kit for PA 46, PA 47
1 Diaphragm actuator
1 Spacer disc
Hand lever for emergency operation
1 Hand lever for emergency operation
1 Forkhead G 10 x 20, DIN 71752
1 Hexagon-head cap screw
Retrofit set for limit switch for MPA 46, MPA 47
2 Proximity switches with L-plugs
2 Isolation amplifiers
2 Mounting brackets
4 Washers
1 Tracing pin

Explanatory Notes - continued -
Description
Intermittent valves for manual or automatic and programme-controlled removing of boiler sludge from
land or marine installations, particularly if these installations are operated without constant supervision
in accordance with TRD 604. Sludge sediments, which are accumulated precipitates from boiler water
that settle at the bottom of the boiler, will be removed from the steam boiler with the the aid of valves
PA and MPA. These valves give the boiler a short blow at regular intervals, thereby discharging
accumulated sludge and sediments.
PA 46 and PA 47 are designed for manual operation (diaphragm actuator can be retrofitted).
MPA 46 and MPA 47 feature a diaphragm actuator for compressed air or pressurized water.
Function
The intermittent valves for removing boiler sludge PA 46 and PA 47 are openend by means of a hand
lever. A pressure pin forces the spring-loaded valve plug out of the valve seat. The large cross-
sectional area of the orifice creates a suction effect, giving a short-term high water flow which will
discharge the precipitated sludge and sediments and - if installed - move them to a mixing cooler
(= blowdown receiver). The intermittent valve for removing boiler sludge must be completely opened
for about 2 seconds with the aid of the hand lever in order to give the boiler a short and highly
effective blow.
The intermittent valves for removing boiler sludge MPA 46 and MPA 47 are openend by the diaphragm
actuator. The guide pin of the diaphragm actuator acts upon the pressure pin, which in turn forces the
spring-loaded valve plug out of the valve seat. The large cross-sectional area of the orifice creates a
suction effect, giving a short-term high water flow which will discharge the precipitated sludge and
sediments and - if installed - move them to a mixing cooler (= blowdown receiver). Compressed air
(at room temperature) or pressurized water (at room temperature) can be used as control fluid for the
diaphragm actuator in accordance with the specified pressure and temperature ratings.
The duration of the bottom blowdown, i. e. the time when the valve is open, should be approx.
2 seconds. The time period when the valve remains closed and hence the frequency of the bottom
blowdown must be established as a function of the size and capacity of the steam boiler.
The duration and frequency of the bottom blowdown must be established individually by the user
as a function of the size and capacity of the steam boiler, the boiler water quality and the
corresponding load.

Technical Data
Name plate / marking
For pressure and temperature ratings see the specification on the valve body or the data given on the
name plate. Further details are given in various GESTRA publications, such as datasheets and technical
information.
In accordance with EN 19, the following type and design data are indicated on the name plate or body:
n Manufacturer
n Type designation
n Pressure class PN or Class
n Material number
n Maximum temperature
n Maximum pressure
n Direction of flow
4
n Stamp on valve body, e. g. 07 specificies the manufacturing quarter and year
(in this case the 4th quarter of 2007)
PA 46 PA 47
max. 55bar@271C
DN 25 PN 40 max.800psi@520F
MADE BY GESTRA AG TMA 300C MADE BY GESTRA AG DN B16.34-CL600
Nominal pressure
Nominal size Max. admissible temperature
Letter M
PA 46 PA 47
max. 55bar@271C
0525 B16.34 CL300 0525 max.800psi@520F
MADE BY GESTRA AG DN TMA 572F MADE BY GESTRA AG DN B16.34-CL600
Fig. 1

Technical Data continued
Dimensions PA 46, PA 47
25
490
350
250
68-108.5
L
Fig. 2

Dimensions MPA 46, MPA 47
235
G 38
25
360
68-108.5
Fig. 3 L
10
End dimensions of flanges (extract)
EN 1092-1 (2001) EN 1092-1 (2001)

DN
l
PN 40 PN 63
[inch] 1 1 1 2 1 1 2
[mm] 15 20 25 32 40 50 25 40 50
D 105 115 140 150 165 140 170 180
b 18 18 18 18 20 24 26 26
k 75 85 100 110 125 100 125 135
g 58 68 78 88 102 68 88 102
l 14 14 18 18 18 18 22 22
n 4 4 4 4 4 4 4 4
L L 150 160 180 200 230 190 220 250
[kg]*) 8.8/13.2 9.3/13.7 10.6/15.0 13.8/18.2 15.6/20.0 9.3/13.7 13.8/18.2 15.6/20.0
*) Weight PA 4... / Weight MPA 4...
ASME B16.5
DN
l Class 150
[inch] 1 1 1 2
[mm] 15 20 25 32 40 50
D 98.4 107.9 117.5 127.0 152.4
b 12.7 14.3 15.9 17.5 19.0
k 69.8 79.4 88.9 98.4 120.6
g 42.9 50.8 63.5 73.0 92.1
l 15.9 15.9 15.9 15.9 19.0
n 4 4 4 4 4
L L 150 160 180 230 230
[kg]*) 8.8/13.2 9.3/13.7 10.6/15.0 13.8/18.2 15.6/20.0
ASME B16.5 ASME B16.5

DN
l Class 300 Class 600
[inch] 1 1 1 2 1 1 2
[mm] 15 20 25 32 40 50 25 40 50
D 117.5 123.8 133.3 155.6 165.1 123.8 155.6 165.1
b 15.9 17.5 19.0 20.6 22.2 17.5 22.2 25.4
k 82.5 88.9 98.4 114.3 127 88.9 114.3 127
g 42.9 50.8 63.5 73.0 92.1 50.8 73.0 92.1
l 19.0 19.0 19.0 22.2 19.0 19.0 22.2 19.0
n 4 4 4 4 4 4 4 4
L L 150 160 180 230 230 216 216 250
[kg]*) 8.8/13.2 9.3/13.7 10.6/15.0 13.8/18.2 15.6/20.0 9.3/13.7 13.8/18.2 15.6/20.0
Other designs, materials and end connections available on request.
11
Dimensions of butt-weld ends (extract)
DIN 3239-1, Series 1 DIN 3239-1, Series 2

DN DIN 2559-2 DIN 2559-2
[inch] 1 1 1 2 1 1 2
[mm] 15 20 25 32 40 50 25 40 50
d2 28 34 43 49 61 34 49 61
L d1 22 28.5 37 43 54.5 28.5 42.5 54.5
for pipe 26.9x2.3 33.7x2.6 42.4x2.6 48.3x2.6 60.3x2.9 33.7x2.6 48.3x2.9 60.3x2.9
L 200 200 200 250 250 200 250 250
[kg]*) 8.2/12.6 8.2/12.6 8.9/13.3 12.0/16.4 13.3/17.7 8.2/12.6 12.0/16.4 13.3/17.7
ASME B16.25, Schedule 40 ASME B16.25, Schedule 80

DN ASME B36.10 ASME B36.10
[inch] 1 1 1 2 1 1 2
[mm] 15 20 25 32 40 50 25 40 50
d2 28 34 43 49 61 34 49 61
L d1 20.9 26.6 35.1 40.9 52.5 24.3 38.1 49.3
for pipe 26.7x2.9 33.4x3.4 42.2x3.6 48.3x3.7 60.3x3.9 33.4x4.5 48.3x5.1 60.3x5.5
L 200 200 200 250 250 200 250 250
[kg]*) 8.2/12.6 8.2/12.6 8.9/13.3 12.0/16.4 13.3/17.7 8.2/12.6 12.0/16.4 13.3/17.7
Dimensions of socket-weld ends (extract)
DIN EN 12760, ASME B16.11

DN Class 3000
[inch] 1 1 1 2
[mm] 15 20 25 32 40 50
d1
d2 40 45 55 62 75
d2
d1 27.3 34.1 42.8 48.8 61.3

b
b 13 13 13 13 16
L for pipe 26.9/26.7 33.7/33.4 42.4/42.2 48.3/48.3 60.3/60.3
L 200 200 200 250 250
[kg]*) 7.4/11.8 7.7/12.1 8.6/13.0 11.4/15.8 12.6/17.0
*) Weight MPA 46 / Weight MPA 47
12
Pressure & temperature ratings / Connections
PA 46, MPA 46, Flanged PN 40, EN 1092-1 (2001), 1.0460 *)

pmax (max. pressure) [bar]g 29
ts (boiling temperature) [C] 234
Calculated according to DIN EN 12516-2 *) Material in accordance with AD bulletin
PA 46, MPA 46, Flanged PN 40, EN 1092-1 (2001), A 105

Calculated according to DIN EN 12516-2
PA 47, MPA 47, Flanged PN 63 / PN 100, EN 1092-1 (2001), 1.0460 *)

Calculated according to DIN EN 12516-2 *) Material in accordance with AD bulletin
PA 47, MPA 47, Flanged PN 63 / PN 100, EN 1092-1 (2001), A 105

Calculated according to DIN EN 12516-2
PA 4..., MPA 4...-ASME, Flanged B16.5 Class 150, Butt-weld ends B16.25, Socket-weld ends B16.11, Class 3000
pmax (max. pressure) [psi]g 203
ts (boiling temperature) [F] 388
Calculated according to ASME B16.34
13
Materials
Type PA... / MPA... PA... / MPA... PA... ASME / MPA... ASME

Designation DIN / EN DIN ASTM
Body P250GH (1.0460) C 22.8 (1.0460) A 105
Stuffing box union P250GH (1.0460) C 22.8 (1.0460) A 105
Sealing plug 42CrMo4 A 193 B7
Gasket X5CrNi18-10 (1.4301) X 5 CrNi 18 10 (1.4301)
Seat, hardened X46Cr13 (1.4034) X 46Cr 13 (1.4034)
Valve cone, hardened X39CrMo17-1 (1.4122) X 35 CrMo 17 (1.4122)
Disk springs 51CrV4 (1.8159) 50 CrV 4 (1.8159)
Compression springs DIN EN 10270-1-SH DIN 17223-C
Diaphragm actuator StW 23 (1.0334)
Packing PTFE-silk
Control membrane EPDM
Corrosion resistance
When used for its intended purpose, the safe functioning of the equipment will not be impaired by
corrosion.
Sizing
The valve body is not designed for pulsating loads. The sizing and anti-corrosion additives reflect the
latest state of technology.
14
Capacity chart PA 46, PA 47, MPA 46, MPA 47
[lb/s] [kg/s]
20
40
30
10
20
8
7
6
50
5 40,
DN
10
4
8
7 3
6
Heiwasserdurchsatz
Capacity of hot water
5 32
0, 25,
of hot water
2
4 D N2
3
Capacity
1 [bar]
2 1 2 3 4 6 8 10 20 30 40 60 80 100
[psi]
10 20 30 40 60 80 100 200 300 400 600 800 1000
Differenzdruck
Differential pressure
Fig. 4 Differential pressure
15
Control pressure chart MPA 46, MPA 47
32
25,
20,
DN
0
,5
40
DN
Boiler pressure
Control pressure
Fig. 5
16
Design
PA 46, PA 47
o 1
n
2
m
t
l
k
j
i 3
h
4
g
f
e
d
c
b 5
a
0 7
9
Fig. 6 8
17
Design continued
MPA 46, MPA 47
o
p
n
t l
k
3
s 4
j
i
h
g
f
e
d
c
b 5
a
0 7
9 8
Fig. 7
18
Design continued
Key
1 Hand lever for PA 46, PA 47

2 Locking lever
3 Distance sleeve
4 Check hole
5 Valve plug
6 Name plate
7 Gasket D 38 x 44 (DN 20-32), D 52 x 60 (DN 40-50)
8 Sealing plug
9 Valve seat
0 Valve body
a Base bushing
b Packing ring 14 x 28 x 7
c Wiper ring
d Pressure ring
e Disc springs (15 pcs.)
f Union nut
g Compression spring
h Check pin
i Pressure sleeve
j Split pin 2.5 x 40, ISO 1234
k Forkhead G 10 x 20, DIN 71752
l Retaining piece
m Guide sleeve
n Pressure plate
o Hexagon-head cap screw M10 x 200, ISO 4014
p Spacer disc
q GESTRA Diaphragm actuator
r Screwed socket (3/8") for control fluid
s Hand lever for emergency operation MPA 46, MPA 47
t Hexagon-head cap screw for forkhead M 10 x 25, ISO 4017
19
Installation
PA 46, PA 47, MPA 46, MPA 47
The intermittent valve for removing boiler sludge can be installed in horizontal or vertical pipes.
The hand lever of the PA 46, PA 47 and the hand lever for the emergency operation of MPA 46, MPA 47
must be freely movable.
Attention
If pressurized water is used as control fluid for the diaphragm actuator make sure that
the control line to the diaphragm actuator is made from corrosion-resistant material.
To avoid waterhammer lay the pipe downstream of the intermittent valve in such a
way that it has a slight fall, or evacuate the pipe before carrying out the boiler blow
down.
The length of the pipe between the steam boiler and the intermittent valve for
removing boiler sludge must not exceed two metres!
Flanged design
1. Observe position of installation. The hand lever 1 or the hand lever for emergency operation s
(MPA...) must be freely movable.
2. Observe the direction of flow. The arrow indicating the flow direction is specified on the name
plate 6.
3. Consider space required for opening the valve. When the intermittent valve for removing boiler
sludge is installed, a minimum space of at least 150 mm is required for removing or retrofitting
the actuator!
4. Remove plastic plugs. They are only used as transit protection.
5. Clean seating surfaces of both flanges.
6. Install intermittent valve for removing boiler sludge.
Socket-weld design
plate 6.
3. Consider space required for opening the valve. When the intermittent valve for removing boiler
sludge is installed a minimum space of at least 150 mm is required for removing or retrofitting
the actuator!
5. Clean socket-weld ends.
6. Arc weld trap only manually (welding processes 111 and 141 in accordance with ISO 4063).
20
Installation continued
Butt-weld design
plate 6.
3. Consider space required for opening the valve. When the intermittent valve for removing boiler sludge
is installed a minimum space of at least 150 mm is required for removing or retrofitting the actuator!
5. Clean butt-weld ends.
6. Arc-weld trap only manually (welding processes 111 and 141 in accordance with ISO 4063)
or use gas welding process (welding process 3 in accordance with ISO 4063).
Attention
Only qualified welders certified e. g. according to DIN EN 287-1 may weld the valve
into lines.
Heat treatment of welds

A subsequent heat treatment of the welds is not required.
Mounting hand lever PA 46, PA 47
1. Release retaining piece for hand lever l and pull it out of the forkhead k.
2. Apply lubricant (e. g. WINIX 5000) to the retaining piece, forkhead and hole for attaching the hand lever.
3. Push hand lever 1 through distance sleeve 3 into the forkhead k and fix it in place by means of
the retaining piece l.
Changing position of hand lever
As standard the hand lever is mounted to the right side of the flow direction. If required by the customer
we can also deliver the hand lever in other positions. To change the position of the hand lever proceed
as follows:
1. Unscrew GESTRA diaphragm actuator q (if installed).
2. Undo retaining piece l and pull out of the forkhead k. Pull hand lever 1 (if installed) out of the
pressure sleeve i.
3. Unscrew hexagon head screws o, remove locking lever 2.
4. Remove pressure plate n and distance sleeve 3.
5. Pull split pin j out of the pressure sleeve i.
6. Turn pressure sleeve i to the left by 90, 180 or 270 depending on the desired position of the
lever.
7. Insert new split pin j into the pressure sleeve i and secure it.
8. Put pressure sleeve n and distance sleeve 3 in place.
9. Mount remaining components in reverse order. Fasten and secure hexagon-head screws o to the
torque indicated in the table Torques required for tightening.
WINIX is a registered trademark of WINIX GmbH, Norderstedt
21
Changing the operating side of the intermittent blowdown valve PA 46 / PA 47
180 90
270 0
Fig. 8
22
Changing the operating side of the intermittent blowdown valve MPA 46 / MPA 47
180 90
270 0
Fig. 9
23
Commissioning
Danger
Risk of severe burns! The hand lever of the intermittent blowdown valve PA 46, PA 47 is
hot during operation. Touching the hot hand lever can cause severe burns.
Use thermally insulated and temperature resistant safety gloves when operating the
valve.
During operation moving internals can pinch ones hands or fingers, causing severe
injuries. Do not touch moving parts.
The intermittent blowdown valves MPA 46, MPA 47 are remote controlled and can open
and close abruptly.
PA 46, PA 47, MPA 46, MPA 47
The flanged connections of the PA 46, PA 47, MPA 46, MPA 47 must be permanently bolted and
leakproof.
After starting up the steam boiler or pressure vessel, the intermittent valve for removing boiler sludge
should be completely opened and closed once. The valve must close automatically, ensuring tight
shut-off.
The stuffing box must be leakproof! Inspect the check hole 4 in order to detect any fluid leakage.
If the equipment is mounted in a new and unpurged installation increase the blowdown frequency
a little at the beginning.
24
Operation
Danger
Risk of severe burns! The hand lever of the intermittent blowdown valve PA 46, PA 47 is
hot during operation. Touching the hot hand lever can cause severe burns.
Use thermally insulated and temperature resistant safety gloves when operating the
valve.
During operation moving internals can pinch ones hands or fingers, causing severe
injuries. Do not touch moving parts.
The intermittent blowdown valves MPA 46, MPA 47 are remote controlled and can open
and close abruptly.
Intermittent boiler blowdown
Simple water treatment processes cannot prevent small amounts of alkaline earths from getting
into the boiler water, thereby causing residual hardness. As a consequence chemical treatment for
removal of hardness in the steam boiler is necessary. The controlled addition of moderate amounts
of excess phosphate ions (phosphate treatment) leads to the precipitation of calcium phosphates
and magnesium phosphates. Both substances form fine sludge deposits which settle out on heating
surfaces and the bottom of the boiler. These sludge deposits can form an adherent insulating coating
on heating surfaces, resulting in an effect similar to that of hard scale. These insulating layers formed
in zones of high heat transfer retard the flow of heat and cause overheating, which may result in
deformation and ultimately failure of the affected boiler parts. It is therefore essential to remove sludge
deposits at regular intervals. Although the use of polyacrylates as complexing agents for removing
residual hardness has a dispersing effect, the free-flowing boiler sludge must also be removed by
blowdown.
Hardness salts and other impurities are kept in suspension by polyacrylates but will eventually over
time settle down on the boiler bottom in the form of finely divided sludge particles. These sludge
deposits impair boiler safety and should be removed by intermittent boiler blowdown.
Duration and frequency of intermittent boiler blowdown
When the GESTRA intermittent valve opens, a localized low-pressure area forms around the blowoff
opening and the boiler sludge rushes out at high velocity, giving the steam boiler a short blow. The
discharge of sludge and precipitated solids (valve fully open) takes approx. 2 seconds. In order to
ascertain the blowdown frequency, the operating data of the installation have to be taken into account.
As ancillary equipment for the intermittent blowdown valves MPA... we recommend the GESTRA
Programme-Controlled Blowdown System TA...
To control the salt content (TDS) of the boiler water we recommend the GESTRA Continuous Blowdown
Valves BA... or BAE...
25
Emergency operation MPA 46, MPA 47
Danger
Risk of severe injuries to the whole body. The intermittent blowdown valves MPA 46,
MPA 47 are remote controlled and can open and close abruptly. Make sure that the line
for the control fluid of the diaphragm actuator is depressurized (zero bar) and isolated
during the emergency operation of the MPA 46, MPA 47.
Insert the hand lever for emergency operation only to operate the valve and remove it
immediately after operation.
Fitting hand lever for emergency operation
1. Fit hand lever for emergency operation s, operate intermittent valve for removing boiler sludge.
2. Remove hand lever for emergency operation s immediately after operation.
Maintenance
GESTRA intermittent valves for removing boiler sludge PA 46, PA 47, MPA 46 and MPA 47 are usually
free of maintenance.
Depending on the quality of the boiler water and the operating mode of the steam generating unit the
equipment may have to be serviced after one to two years of operation.
Retightening stuffing box
If fluid escapes through the check hole 4 the union nut f of the stuffing box must be retightened:
1. Observe danger note on page 4.
2. Insert pin punch through the opening in the distance sleeve 3 into one of the holes of the union nut
f; carefully tighten it clockwise by hand until no more fluid escapes through the check hole 4.
3. Open the intermittent blowdown valve completely. The stuffing box must not leak.
4. Check control hole 4 for leaks. If fluid escapes, retighten stuffing box. The valve must close auto
matically without leaking.
Attention
Replace internals of stuffing box if it can no longer be retightened by tightening the

union nut f.
Loosen the union nut f a little if the force of the spring does not suffice to close the
valve automatically. If fluid escapes through the check hole all internals of the stuffing
box must be replaced.
26
Maintenance continued
Replacing stuffing box PA 46, PA 47
1. Observe danger note on page 4!

2. Undo retaining piece l for forkhead k and pull out hand lever 1. Fig. 6
3. Unscrew hexagon-head cap screws o and remove locking lever 2.
5. Pull out split pin j.
6. Use open-end spanner A. F. 28 mm to unscrew the pressure sleeve i from the valve plug 5.
7. Remove compression spring g.
8. Use open-end spanner A. F. 32 mm to unscrew the union nut f.
9. Unscrew sealing plug 8 and remove gasket 7.
10. Pull out valve plug 5.
11. Take out internal parts e d c b a of stuffing box.
12. Clean stuffing box, valve body and valve plug.
13. Re-insert valve plug 5 and use abrasive paste type TETRABOR F400 for polish grinding.
14. Insert new gasket 7 and screw in sealing plug 8. Tighten with the torque indicated in the table
Torques required for tightening.
15. Re-insert internal parts of stuffing box according to order as specified in Fig. 6, Fig. 7, Fig. 10
16. Apply heat-resistance lubricant to stuffing box thread (use e.g. WINIX 2150).
17. Align valve plug 5 such that the hole for the split pin j is perpendicular to the flow direction of the
intermittent valve.
18. Use open-end spanner A. F. 32 mm to screw in union nut f and tighten at room temperature with
the torque indicated in the table Torques required for tightening.
19. Apply heat-resistant lubricant to both sides of the compression spring g (use e. g. WINIX 2150)
and place it onto the union nut f.
20. Use open-end spanner A. F. 28 mm to screw the pressure sleeve i onto the valve plug 5 until the
holes for the split pin j in the valve plug and the pressure pin overlap.
21. Insert split pin j.
22. Re-insert distance sleeve 3 and pressure plate n. Align check hole 4 to the right.
23. Insert and screw in hexagon-head cap screws o and locking lever 2 (only with PA 46, PA 47) and
tighten them in diagonally opposite pairs with the torque indicated in the table Torques required
for tightening.
24. Insert hand lever 1 and fix it to the forkhead k by means of retaining piece l.
25. Operate valve once (open it until it hits the stop). The stuffing box must be tight!

TETRABOR is a registered trademark of Wacker-Chemie GmbH, Kempten
27
Replacing stuffing box, valve seat and valve plug PA 46, PA 47

2. Undo retaining piece l for forkhead k and pull out hand lever 1. Fig. 6
5. Pull out split pin j.
6. Use open-end spanner A. F. 28 mm to unscrew the pressure sleeve i from the valve plug 5.
7. Remove compression spring g.
8. Use open-end spanner A. F. 32 mm to unscrew the union nut f.
9. Unscrew sealing plug 8 and remove gasket 7.
10. Pull out valve plug 5.
11. Take out internal parts e d c b a of stuffing box.
12. Use steel punch to knock the valve seat 9 out of the valve body 0. Fig. 12
13. Clean stuffing box and valve body.
14. Insert new valve seat 9 such that two opposite holes are in the flow direction of the intermittent
valve.
15. Use punch made of CuZn to fix the valve seat in the valve body. Fig. 13
16. Re-insert valve plug 5 and use abrasive paste type TETRABOR F400 for polish grinding.
17. Insert new gasket 7 and screw in sealing plug 8. Tighten with the torque indicated in the table
18. Re-insert internal parts of stuffing box according to order as specified in Fig. 6, Fig. 7, Fig. 10
19. Apply heat-resistance lubricant to stuffing box thread (use e.g. WINIX 2150).
20. Align valve plug 5 such that the hole for the split pin j is perpendicular to the flow direction of the
intermittent valve.
21. Use open-end spanner A. F. 32 mm to screw in union nut f and tighten at room temperature with
22. Apply heat-resistant lubricant to both sides of the compression spring g (use e. g. WINIX 2150)
and place it onto the union nut f.
23. Use open-end spanner A. F. 28 mm to screw the pressure sleeve i onto the valve plug 5 until the
holes for the split pin j in the valve plug and the pressure pin overlap.
24. Insert split pin j.
25. Put distance sleeve 3 and pressure plate n in place. Align check hole 4 to the right.
26. Insert and screw in hexagon-head cap screws o and locking lever 2 (only with PA 46, PA 47) and
tighten them in diagonally opposite pairs with the torque indicated in the table Torques required
for tightening.
27. Insert hand lever 1 and fix it to the forkhead k by means of retaining piece l.

TETRABOR is a registered trademark of Wacker-Chemie GmbH, Kempten
28
Replacing stuffing box MPA 46, MPA 47

2. Detach pressure line for the control fluid of the diaphragm actuator from the screwed socket r.
3. Remove diaphragm actuator q. Fig. 7
4. Proceed as described under Replacing stuffing box PA 46, PA 47, items 2 to 23.
24. Put spacer disk p onto pressure plate n.
25. Screw on diaphragm actuator q with the torque indicated in the table Torques required for
tightening.
26. Attach pressure line for the control fluid of the diaphragm actuator.
29
Replacing stuffing box, valve seat and valve plug MPA 46, MPA 47

2. Detach pressure line for the control fluid of the diaphragm actuator from the screwed socket r.
3. Remove diaphragm actuator q. Fig. 7
4. Proceed as described under Replacing stuffing box, valve seat and valve plug PA 46, PA 47,
items 2 to 26.
tightening.
30
Replacing control membrane in diaphragm actuator MPA 46, MPA 47

2. Detach pressure line for the control fluid of the diaphragm actuator.
3. Unscrew hexagon-head bolts u and hexagon nuts. Fig. 14
4. Remove and clean upper part v of the diaphragm actuator.
5. Take out old control membrane w. Clean lower part x.
6. Insert new control membrane w, aligning its holes with the holes of the lower part.
7. Put upper part v on top and align its holes with the holes of the control membrane and the
lower part.
8. Insert hexagon-head bolts u and tighten them with the respective hexagon nuts in diagonally
opposite pairs to the torque indicated in the table Torques required for tightening.
10. Check tightness. If necessary retighten hexagon-head bolts u carefully in diagonally opposite
pairs.
11. To grease the guide plate pin y apply lubricant to the grease nipple in the connecting socket of the
diaphragm actuator (use e. g. WINIX 5000).
Attention
The torque for tightening the hexagon-head cap screws u must not exceed 5 Nm
because higher torques could damage the control membrane!
31
Torques required for tightening
Item Intermittent valves for removing boiler sludge Torques [Nm]
8 PA 46, PA 47, MPA 46, MPA 47 350
f PA 46, PA 47, MPA 46, MPA 47 55
o PA 46, PA 47, MPA 46, MPA 47 20
q MPA 46, MPA 47 120
u MPA 46, MPA 47 5

All torques indicated in the table are based at a room temperature of 20 C.
Tools
Combination spanner A. F. 13 mm, DIN 3113, Form B

Torque spanner 1 - 12 Nm, ISO 6789
Socket spanner 13 x 250, DIN 3112
Punch 20 x 200, made of steel
Punch 20 x 200, made of CuZn (brass)
Pin punch 8 x 150, DIN 6450 C
Grease gun (for valve plug)
32
Single parts of stuffing box, valve plug, valve seat
d
c
a
9
Fig. 10 5
Fig. 11
33
Mounting / removing valve seat
Fig. 12
Fig. 13
34
Mounting / removing control membrane
Fig. 14
y
35
Key
u Hexagon-head bolt M8 with hexagon nut M8

v Upper part of the diaphragm actuator
w Control membrane
x Lower part of the diaphragm actuator with connector socket
y Guide pin with plate
z Mounting bracket
A Tracing pin
B Limit switch (proximity switch with L plug)
C Washer
D Hexagon nut
Retrofitting
GESTRA intermittent valves PA 46 and PA 47 can be retrofitted with a GESTRA diaphragm actuator
(MPA 46, MPA 47).
Danger
Risk of severe burns and scalds to the whole body!

Before carrying out any retrofitting work on the valve or loosening flanged connections,
stuffing box unions or sealing plugs make sure that all connected lines are depressurized
(zero bar) and cooled down to room temperature (20 C).
Insert the hand lever for emergency operation s only to operate the valve and remove it
immediately after operation.
36
Retrofitting continued
Mounting diaphragm actuator

2. Undo centering screw m. Fig. 6
3. Undo retaining piece l for forkhead k and pull out hand lever 1. Note that the hand lever must
not be mounted again!
4. Snap retaining piece l on forkhead k.
6. Insert hexagon-head cap screws o and tighten them with the torque indicated in the table
8. Apply heat-resistant lubricant to the connector socket of the diaphragm actuator
(use e.g. WINIX 2150).
tightening.
10. Attach pressure line (3/8") for the control fluid of the diaphragm actuator.
Mounting an existing MPA 26, MPA 27 diaphragm actuator

2. Unscrew hexagon head bolts u and hexagon nuts, Fig. 14.
3. Remove upper part v from diaphragm actuator, take out control membrane w.
4. Remove guide pin with plate y.
5. Insert new guide pin with plate y of the retrofit kit.
6. Put upper part v in place and align its holes with the holes of the control membrane plate.
7. Insert hexagon head bolts u, fasten with hexagon nuts and tighten them in diagonally opposite
pairs with the torque indicated in the table Torques required for tightening.
9. Check tightness. If necessary retighten hexagon-head bolts u carefully in diagonally opposite
pairs.
10. To grease the guide plate y apply lubricant to the grease nipple in the connecting socket of the
diaphragm actuator (use e. g. WINIX 5000).
37
Mounting the forkhead (hand lever for emergency operation)

2. Align and fit forkhead k together with hexagon-head cap screw t to the pressure plate n.
Tighten the hexagon-head cap screw t with the torque indicated in the table Torques required
for tightening. Fig. 7
3. Fit hand lever for emergency operation s, operate intermittent valve for removing boiler sludge.
4. Remove hand lever for emergency operation s immediately after operation.
Mounting the limit switch (proximity switch)

2. Detach pressure line for the control of the diaphragm actuator from the screwed socket r.
3. Detach diaphragm actuator q, Fig. 7.
4. Remove spacer disk p and pressure plate n.
5. Unscrew and take out hexagon-head screws o.
6. Push mounting bracket z over the hexagon-head screws.
7. Screw in hexagon-head screws o and fasten them in diagonally opposite pairs with the torque
indicated in the table Torques required for tightening.
9. Screw diaphragm actuator q in place and fasten with the torque indicated in the table Torques
required for tightening.
11. Operate the intermittent blowdown valve once.
12. Remove check pin h and replace it with tracing pin A. Use screw locking glue (e. g. Loctite 620)
to fix the tracing pin.
13. Put the proximity switch B into the mounting bracket z, align the proximity switch as shown in
Fig. 16, Fig. 17 and fix it with washers C and hexagon-head bolts D. Fasten hexagon nuts with
14. Connect the proximity switch B to the isolation amplifier as specified in the installation instruc
tions of the manufacturer.
15. Operate the intermittent blowdown valve once (open it until it hits the stop). The stuffing box must
be tight!
17. Check performance of the proximity switch.
Loctite is a registered trademark of HENKEL KGaA, Dsseldorf
38
Mounting the limit switch (proximity switch) continued
A B
z
B
D
B
Fig. 16 C C
D
Fig. 15
B
A
min. 0.80,8/ max.
min. 1.61,6
/ max.
min.
min.0.032"
0,032 / max. 0.063"
/ max. 0,063
Fig. 17
39
Tools

Torques required for tightening
Item Intermittent valves for removing boiler sludge Torques [Nm]
o PA 46, PA 47, MPA 46, MPA 47 20
q MPA 46, MPA 47 120
t MPA 46, MPA 47 20
D MPA 46, MPA 47 12

All torques indicated in the table are based at a room temperature of 20 C.
40
Spare Parts
Spare parts list
Stock code Stock code

Item Designation
PA 46, PA 47 MPA 46, MPA 47
Internal parts of stuffing box, DN 20 to DN 50:

ab Base bushing, wiper ring,
cd Packing ring 14 x 28 x 7, pressure ring, 335 064 335 064
Disk springs (15 pcs.),
e7 Gasket D 38 x 44, D 52 x 60
Valve plug, valve seat and internal parts

59 of stuffing box, DN 20, DN 25, DN 32:
ab Base bushing, wiper ring, 335 063 335 063
cd Packing ring 14 x 28 x 7, pressure ring,
e7 Gasket D 38 x 44
Valve plug, valve seat and internal parts

59 of stuffing box, DN 40, DN 50:
ab Base bushing, wiper ring, 335 065 335 065
cd Packing ring 14 x 28 x 7, pressure ring,
e7 Gasket D 52 x 60
w Control membrane for diaphragm actuator 335 131
sltk Hand lever for emergency operation with forkhead 335 060
yp Guide pin with plate, spacer disk 335 130
qp Diaphragm actuator with spacer disk 335 093
41
Parts for retrofitting
List of parts for retrofitting
Stock code Stock code

Item Designation
PA 46, PA 47 MPA 46, MPA 47
qp Diaphragm actuator with spacer disk 335 093
Guide sleeve with plate, spacer disk (for retrofitting

yp MPA 26, MPA 27 to MPA 46, MPA 47)
335 130
sltk Hand lever for emergency operation with forkhead 335 060
zA Proximity switch, including isolation amplifier and

335140
BC D L-plug
Decommissioning
Danger
Risk of severe burns and scalds to the whole body!

Before loosening flanged connections, stuffing box unions or sealing plugs make sure
that all connected lines are depressurized (zero bar) and cooled down to room
temperature (20 C).
Disposal
Dismantle the valve and separate the waste materials, using the material specifications in the table
Technical Data as reference.
For the disposal of the valve observe the pertinent legal regulations concerning waste disposal.
42
Annex
Declaration of Conformity
We hereby declare that the pressure equipment PA 46, PA 47, MPA 46 and MPA 47 conform to the
following European Directives:
Pressure Equipment Directive 97/23/EC of 29 May 1997 for equipment of category 1 according to
the table Pressure Equipment Directive on page 5.
ATEX Directive 94/9/EC of 23 March 1994.
Applied conformity assessment procedure according to 97/23/EC: Annex III, Module H, verified by the
Notified Body 0525.
Applied conformity assessment procedure according to 94/9/EC: Annex VIII.
This declaration is no longer valid if modifications are made to the equipment without consulation with us.
Bremen, 30th November 2004

GESTRA AG
Dipl.-Ing. Uwe Bledschun Dipl.-Ing. Lars Bohl

(Academically qualified engineer) (Academically qualified engineer)
Head of the Design Dept. Quality Assurance Manager
43
GESTRA
Agencies all over the world:

www.gestra.de
Great Britain South Africa

Flowserve GB Limited Flowserve SA (Pty) Ltd.
Abex Road Unit No. 1
Newbury, Berkshire RG14 5EY Director Road
Tel. 0044 16 35 / 46 99 90 Spartan Extension 2
Fax 0044 16 35 / 3 60 34 Kempton Park 1613
E-mail [email protected] Tel. 0027 11 / 9 23 73 00
Web www.flowserve.com Fax 0027 11 / 9 74 64 20
E-Mail [email protected]
Web www.flowserve.com
Singapore
Flowserve Pte. Ltd. USA
12 Tuas Avenue 20
Singapore 63882 Flowserve GESTRA U.S.
Tel. 0065 / 68 79 89 00 2341 Ampere Drive
Fax 0065 / 68 62 49 40 Louisville, KY 40299
E-Mail [email protected] Tel. 001 502 / 267-22 05
Web www.gestra.com Fax 001 502 / 266-53 97
E-mail [email protected]
GESTRA AG
P. O. Box 10 54 60, D-28054 Bremen
Mnchener Str. 77, D-28215 Bremen
Telephone 0049 (0) 421 35 03 - 0
Fax 0049 (0) 421 35 03 - 393
E-Mail [email protected]
Internet www.gestra.de
81844701/808cm 2004 GESTRA AG Bremen Printed in Germany

44

PA 46 PA 47 MPA 46 MPA 47: GESTRA Steam Systems

Uploaded by

Copyright:

Available Formats

PA 46 PA 47 MPA 46 MPA 47: GESTRA Steam Systems

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

PA 46 PA 47 MPA 46 MPA 47: GESTRA Steam Systems

Uploaded by

Copyright:

Available Formats

What is the document about?

What is the document about?

What safety precautions are mentioned?

What safety precautions are mentioned?

GESTRA Steam Systems

Emergency operation MPA 46, MPA 47

Parts for retrofitting

Usage for the intended purpose

PA 46, PA 47, MPA 46, MPA 47:

The valve is under pressure during operation.

PED (Pressure Equipment Directive)

ATEX (Atmosphre Explosible)

Name plate / marking

Dimensions MPA 46, MPA 47

End dimensions of flanges (extract)

EN 1092-1 (2001) EN 1092-1 (2001)

ASME B16.5 ASME B16.5

Dimensions of butt-weld ends (extract)

DIN 3239-1, Series 1 DIN 3239-1, Series 2

ASME B16.25, Schedule 40 ASME B16.25, Schedule 80

Dimensions of socket-weld ends (extract)

DIN EN 12760, ASME B16.11

d1 27.3 34.1 42.8 48.8 61.3

Pressure & temperature ratings / Connections

PA 46, MPA 46, Flanged PN 40, EN 1092-1 (2001), 1.0460 *)

PA 46, MPA 46, Flanged PN 40, EN 1092-1 (2001), A 105

PA 47, MPA 47, Flanged PN 63 / PN 100, EN 1092-1 (2001), 1.0460 *)

PA 47, MPA 47, Flanged PN 63 / PN 100, EN 1092-1 (2001), A 105

Type PA... / MPA... PA... / MPA... PA... ASME / MPA... ASME

Capacity chart PA 46, PA 47, MPA 46, MPA 47

Control pressure chart MPA 46, MPA 47

MPA 46, MPA 47

1 Hand lever for PA 46, PA 47

PA 46, PA 47, MPA 46, MPA 47

Heat treatment of welds

Mounting hand lever PA 46, PA 47

Changing position of hand lever

Changing the operating side of the intermittent blowdown valve PA 46 / PA 47

PA 46, PA 47, MPA 46, MPA 47

Intermittent boiler blowdown

Duration and frequency of intermittent boiler blowdown

Fitting hand lever for emergency operation

Retightening stuffing box

Replace internals of stuffing box if it can no longer be retightened by tightening the

Replacing stuffing box PA 46, PA 47

1. Observe danger note on page 4!

WINIX is a registered trademark of WINIX GmbH, Norderstedt

Replacing stuffing box, valve seat and valve plug PA 46, PA 47

1. Observe danger note on page 4!

WINIX is a registered trademark of WINIX GmbH, Norderstedt

Replacing stuffing box MPA 46, MPA 47

1. Observe danger note on page 4!

1. Observe danger note on page 4!

Replacing control membrane in diaphragm actuator MPA 46, MPA 47

1. Observe danger note on page 4!

WINIX is a registered trademark of WINIX GmbH, Norderstedt

Torques required for tightening

Item Intermittent valves for removing boiler sludge Torques [Nm]

8 PA 46, PA 47, MPA 46, MPA 47 350