PA 46 PA 47 MPA 46 MPA 47

GESTRA Steam Systems PA 46 PA 47 MPA 46 MPA 47 EN English Installation Instructions 818447 01 Rapid Action Intermittent Valve for Removing Boiler Sludge PA 46, PA 47, MPA 46, MPA 47

Contents Important Notes Usage for the intended purpose...4 Safety note...4 Danger...4 Attention...4 PED (Pressure Equipment Directive)...5 ATEX (Atmosphère 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 Page

Contents - continued - 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 Page 3

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 one s 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. 4

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 (Atmosphère 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. 5

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 1 Installation manual MPA 46 1 Intermittent valve for removing boiler sludge MPA 46 1 Installation manual MPA 47 1 Intermittent valve for removing boiler sludge MPA 47 1 Installation manual Retrofitting kit for PA 46, PA 47 1 Diaphragm actuator 1 Spacer disc 1 Installation manual 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 1 Installation manual 6

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 crosssectional 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. 7

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 4 th quarter of 2007) 0525 MADE BY GESTRA AG PA 46 DN 25 PN 40 MADE BY GESTRA AG TMA 300 C Nominal pressure Nominal size Max. admissible temperature PA 46 B16.34 CL300 DN TMA 572 F MADE BY GESTRA AG MADE BY GESTRA AG PA 47 max. 55bar@271 C 0525 max.800psi@520 F DN PA 47 max. 55bar@271 C max.800psi@520 F DN Letter M B16.34-CL600 B16.34-CL600 Fig. 1 8

Technical Data continued Dimensions PA 46, PA 47 25 490 350 250 L 68-108.5 Fig. 2 9

Technical Data continued Dimensions MPA 46, MPA 47 235 25 G 3 8 360 Fig. 3 L 68-108.5 10

Technical Data continued End dimensions of flanges (extract) L *) Weight PA 4... / Weight MPA 4... L *) Weight PA 4... / Weight MPA 4... L l l l DN EN 1092-1 (2001) EN 1092-1 (2001) PN 40 PN 63 [inch] ½ ¾ 1 1¼ 1½ 2 1 1½ 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 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 DN ASME B16.5 Class 150 [inch] ½ ¾ 1 1¼ 1½ 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 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 DN ASME B16.5 Class 300 ASME B16.5 Class 600 [inch] ½ ¾ 1 1¼ 1½ 2 1 1½ 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 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 *) Weight PA 4... / Weight MPA 4... Other designs, materials and end connections available on request. 11

Technical Data continued Dimensions of butt-weld ends (extract) L *) Weight PA 4... / Weight MPA 4... L DN DIN 3239-1, Series 1 DIN 3239-1, Series 2 DIN 2559-2 DIN 2559-2 [inch] ½ ¾ 1 1¼ 1½ 2 1 1½ 2 [mm] 15 20 25 32 40 50 25 40 50 d 2 28 34 43 49 61 34 49 61 d 1 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 DN ASME B16.25, Schedule 40 ASME B36.10 ASME B16.25, Schedule 80 ASME B36.10 [inch] ½ ¾ 1 1¼ 1½ 2 1 1½ 2 [mm] 15 20 25 32 40 50 25 40 50 d 2 28 34 43 49 61 34 49 61 d 1 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 *) Weight PA 4... / Weight MPA 4... Other designs, materials and end connections available on request. Dimensions of socket-weld ends (extract) b L d1 d2 DN DIN EN 12760, ASME B16.11 Class 3000 [inch] ½ ¾ 1 1¼ 1½ 2 [mm] 15 20 25 32 40 50 d 2 40 45 55 62 75 d 1 27.3 34.1 42.8 48.8 61.3 b 13 13 13 13 16 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 Other designs, materials and end connections available on request. 12

Technical Data continued Pressure & temperature ratings / Connections PA 46, MPA 46, Flanged PN 40, EN 1092-1 (2001), 1.0460*) p max (max. pressure) [bar]g 29 t s (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 p max (max. pressure) [bar]g 36 t s (boiling temperature) [ C] 246 Calculated according to DIN EN 12516-2 PA 47, MPA 47, Flanged PN 63 / PN 100, EN 1092-1 (2001), 1.0460*) p max (max. pressure) [bar]g 44 t s (boiling temperature) [ C] 257 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 p max (max. pressure) [bar]g 55 t s (boiling temperature) [ C] 271 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 p max (max. pressure) [bar]g 14 t s (boiling temperature) [ C] 198 p max (max. pressure) [psi]g 203 t s (boiling temperature) [ F] 388 Calculated according to ASME B16.34 PA 4..., MPA 4...-ASME, Flanged B16.5 Class 300, Butt-weld ends B16.25, Socket-weld ends B16.11, Class 3000 p max (max. pressure) [bar]g 42 t s (boiling temperature) [ C] 254 p max (max. pressure) [psi]g 609 t s (boiling temperature) [ F] 489 Calculated according to ASME B16.34 PA 4..., MPA 4...-ASME, Flanged B16.5 Class 600, Butt-weld ends B16.25, Socket-weld ends B16.11, Class 3000 p max (max. pressure) [bar]g 55 t s (boiling temperature) [ C] 271 p max (max. pressure) [psi]g 800 t s (boiling temperature) [ F] 520 Calculated according to ASME B16.34 13

Technical Data continued 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

Technical Data continued Capacity chart PA 46, PA 47, MPA 46, MPA 47 [lb/s] 40 [kg/s] 20 30 Capacity of hot water Heißwasserdurchsatz Capacity of hot water Fig. 4 20 10 8 7 6 5 4 3 2 10 8 7 6 5 4 3 2 1 1 2 3 Differenzdruck Differential pressure [bar] 4 6 8 10 20 30 40 60 80100 10 20 30 40 60 80 100 200 300 400 600 800 1000 Differential pressure DN 40, 50 DN 20, 25, 32 [psi] 15

Technical Data continued Control pressure chart MPA 46, MPA 47 DN 20, 25, 32 DN 40, 50 Boiler pressure Fig. 5 Control pressure 16

Design PA 46, PA 47 o 1 n m l k j i h g t 2 3 4 f e d c b a 5 6 Fig. 6 0 9 7 8 17

Design continued MPA 46, MPA 47 r q p n o k s t l 3 4 j i h g f e d c b a 5 6 Fig. 7 0 9 7 8 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 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 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 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 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

Installation continued Changing the operating side of the intermittent blowdown valve PA 46 / PA 47 180 90 270 0 Fig. 8 22

Installation continued 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 one s 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 one s 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. 4. Remove pressure plate n and distance sleeve 3. 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! 26. Check control hole 4 for leaks. If fluid escapes, retighten stuffing box. The valve must close auto matically without leaking. WINIX is a registered trademark of WINIX GmbH, Norderstedt TETRABOR is a registered trademark of Wacker-Chemie GmbH, Kempten 27

Maintenance continued 28 Replacing stuffing box, valve seat and valve plug 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. 4. Remove pressure plate n and distance sleeve 3. 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 Torques required for tightening. 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 the torque indicated in the table Torques required for tightening. 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. 28. Operate valve once (open it until it hits the stop). The stuffing box must be tight! 29. Check control hole 4 for leaks. If fluid escapes, retighten stuffing box. The valve must close auto matically without leaking. WINIX is a registered trademark of WINIX GmbH, Norderstedt TETRABOR is a registered trademark of Wacker-Chemie GmbH, Kempten

Maintenance continued Replacing stuffing box MPA 46, MPA 47 1. Observe danger note on page 4! 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. 27. Operate valve once (open it until it hits the stop). The stuffing box must be tight! 28. Check control hole 4 for leaks. If fluid escapes, retighten stuffing box. The valve must close auto matically without leaking. 29

Maintenance continued Replacing stuffing box, valve seat and valve plug MPA 46, MPA 47 1. Observe danger note on page 4! 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. 27. Put spacer disk p onto pressure plate n. 28. Screw on diaphragm actuator q with the torque indicated in the table Torques required for tightening. 29. Attach pressure line for the control fluid of the diaphragm actuator. 30. Operate valve once (open it until it hits the stop). The stuffing box must be tight! 31. Check control hole 4 for leaks. If fluid escapes, retighten stuffing box. The valve must close auto matically without leaking. 30

Maintenance continued Replacing control membrane in diaphragm actuator MPA 46, MPA 47 1. Observe danger note on page 4! 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. 9. Attach pressure line for the control fluid of the diaphragm actuator. 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! WINIX is a registered trademark of WINIX GmbH, Norderstedt 31

Maintenance continued 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 Combination spanner A. F. 16 mm, DIN 3113, Form B Combination spanner A. F. 17 mm, DIN 3113, Form B Combination spanner A. F. 28 mm, DIN 3113, Form B Combination spanner A. F. 32 mm, DIN 3113, Form B Combination spanner A. F. 36 mm, DIN 3113, Form B Combination spanner A. F. 41 mm, DIN 3113, Form B Torque spanner 1-12 Nm, ISO 6789 Torque spanner 20-120 Nm, ISO 6789 Torque spanner 80-400 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

Maintenance continued Single parts of stuffing box, valve plug, valve seat e d c b c Fig. 10 a 9 5 Fig. 11 33

Maintenance continued Mounting / removing valve seat Fig. 12 Fig. 13 34

Maintenance continued Mounting / removing control membrane u v w x Fig. 14 y 35

Maintenance continued 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 1. Observe danger note on page 4! 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. 5. Unscrew hexagon-head cap screws o and remove locking lever 2. 6. Insert hexagon-head cap screws o and tighten them with the torque indicated in the table Torques required for tightening. 7. Put spacer disk p onto pressure plate n. 8. Apply heat-resistant lubricant to the connector socket of the diaphragm actuator (use e.g. WINIX 2150). 9. Screw on diaphragm actuator q with the torque indicated in the table Torques required for tightening. 10. Attach pressure line ( 3 /8") for the control fluid of the diaphragm actuator. 11. Operate valve once (open it until it hits the stop). The stuffing box must be tight! 12. Check control hole 4 for leaks. If fluid escapes, retighten stuffing box. The valve must close auto matically without leaking. Mounting an existing MPA 26, MPA 27 diaphragm actuator 1. Observe danger note on page 4. 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. 8. Attach pressure line for the control fluid of the diaphragm actuator. 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). WINIX is a registered trademark of WINIX GmbH, Norderstedt 37

Retrofitting continued Mounting the forkhead (hand lever for emergency operation) 1. Observe danger note on page 4. 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) 1. Observe danger note on page 4. 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. 8. Put spacer disk p onto pressure plate n. 9. Screw diaphragm actuator q in place and fasten with the torque indicated in the table Torques required for tightening. 10. Attach pressure line for the control fluid of the diaphragm actuator. 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 the torque indicated in the table Torques required for tightening. 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! 16. Check control hole 4 for leaks. If fluid escapes, retighten stuffing box. The valve must close auto matically without leaking. 17. Check performance of the proximity switch. 38 Loctite is a registered trademark of HENKEL KGaA, Düsseldorf

Retrofitting continued Mounting the limit switch (proximity switch) continued B A B Fig. 16 z B C D C D Fig. 15 B B A min. min. 0.80,8 / max. / max. 1.61,6 min. min. 0.032" 0,032 / max. / max. 0.063" 0,063 Fig. 17 39

Retrofitting continued Tools Combination spanner A. F. 16 mm, DIN 3113, Form B Combination spanner A. F. 17 mm, DIN 3113, Form B Combination spanner A. F. 41 mm, DIN 3113, Form B Torque spanner 20-120 Nm, ISO 6789 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 Item Designation Stock code Stock code PA 46, PA 47 MPA 46, MPA 47 a b c d e 7 Internal parts of stuffing box, DN 20 to DN 50: Base bushing, wiper ring, Packing ring 14 x 28 x 7, pressure ring, Disk springs (15 pcs.), Gasket D 38 x 44, D 52 x 60 335 064 335 064 5 9 a b c d e 7 5 9 a b c d e 7 Valve plug, valve seat and internal parts of stuffing box, DN 20, DN 25, DN 32: Base bushing, wiper ring, Packing ring 14 x 28 x 7, pressure ring, Disk springs (15 pcs.), Gasket D 38 x 44 Valve plug, valve seat and internal parts of stuffing box, DN 40, DN 50: Base bushing, wiper ring, Packing ring 14 x 28 x 7, pressure ring, Disk springs (15 pcs.), Gasket D 52 x 60 335 063 335 063 335 065 335 065 w Control membrane for diaphragm actuator 335 131 s l t k Hand lever for emergency operation with forkhead 335 060 y p Guide pin with plate, spacer disk 335 130 q p Diaphragm actuator with spacer disk 335 093 41

Parts for retrofitting List of parts for retrofitting Item Designation Stock code Stock code PA 46, PA 47 MPA 46, MPA 47 q p Diaphragm actuator with spacer disk 335 093 y p Guide sleeve with plate, spacer disk (for retrofitting MPA 26, MPA 27 to MPA 46, MPA 47) 335 130 s l t k Hand lever for emergency operation with forkhead 335 060 z A B C D Proximity switch, including isolation amplifier and L-plug 335140 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, 30 th November 2004 GESTRA AG Dipl.-Ing. Uwe Bledschun (Academically qualified engineer) Head of the Design Dept. Dipl.-Ing. Lars Bohl (Academically qualified engineer) Quality Assurance Manager 43

GESTRA Agencies all over the world: www.gestra.de Great Britain Flowserve GB Limited Abex Road Newbury, Berkshire RG14 5EY Tel. 0044 16 35 / 46 99 90 Fax 0044 16 35 / 3 60 34 E-mail gestraukinfo@flowserve.com Web www.flowserve.com Singapore Flowserve Pte. Ltd. 12 Tuas Avenue 20 Singapore 63882 Tel. 0065 / 68 79 89 00 Fax 0065 / 68 62 49 40 E-Mail fcd_gestra_singapore@flowserve.com Web www.gestra.com South Africa Flowserve SA (Pty) Ltd. Unit No. 1 Director Road Spartan Extension 2 Kempton Park 1613 Tel. 0027 11 / 9 23 73 00 Fax 0027 11 / 9 74 64 20 E-Mail tvniekerk@flowserve.com Web www.flowserve.com USA Flowserve GESTRA U.S. 2341 Ampere Drive Louisville, KY 40299 Tel. 001 502 / 267-22 05 Fax 001 502 / 266-53 97 E-mail fcd-gestra-usa@flowserve.com GESTRA AG P. O. Box 10 54 60, D-28054 Bremen Münchener Str. 77, D-28215 Bremen Telephone 0049 (0) 421 35 03-0 Fax 0049 (0) 421 35 03-393 E-Mail gestra.ag@flowserve.com Internet www.gestra.de 818447 01/808cm 2004 GESTRA AG Bremen Printed in Germany 44