Spirax Sarco BM series Bedienungsanleitung

IM-S21-01 CH Issue 7 1

1. General

safety information

2. Technical details

3. Installation and

commissioning

4. Maintenance

5. Spare parts

SA Control Valve types:

BM, BMF, BX, SB, NS, KA, KB, KC (Normally open)

BMRA, BMFRA, BXRA, SBRA, NSRA, KX, KY (Normally closed)

Installation and Maintenance Instructions

IM-S21-01

CH Issue 7

0366055/7

IM-S21-01 CH Issue 7

1. General safety information

Safe operation of these products can only be guaranteed if they are properly

installed, commissioned, used and maintained by qualified personnel (see

Section 1.11 ) in compliance with the operating instructions. General installation and

safety instructions for pipeline and plant construction, as well as the proper use of

tools and safety equipment must also be complied with.

Warning - Laminated gaskets

The metal foil sheet used to reinforce gaskets is very thin and sharp. Care should be taken

when handling to avoid the possibility of cuts or lacerations to fingers or hands.

1.1 Intended use

Referring to the Installation and Maintenance Instructions, name-plate and Technical

Information Sheet, check that the product is suitable for the intended use/application.

The products listed below comply with the requirements of the European Pressure

Equipment Directive 97/23/EC and carry the mark when so required. The products fall

within the following Pressure Equipment Directive categories:

Group 2 Group 2

Product Gases Liquids

BX, BXRA, BM, BMRA, BMF, BMFRA, SB and SBRA SEP SEP

KA, KB, KC, KX, KY31 and KY33 SEP SEP

KA, KB, KC, KX and KY43 DN15 - 32 SEP SEP

DN40 - 50 1 SEP

KA, KB, KC, KX and KY51 DN15 - 40 SEP SEP

DN50 1 SEP

KA61, KA63 and KC63 DN15 - 32 SEP SEP

KA and KC63 DN40 - 50 1 SEP

NS and NSRA 1 SEP

i) The products have been specifically designed for use on steam, water and other

non-hazardous fluids which are in Group 2 of the above mentioned Pressure

Equipment Directive. The products’ use on other fluids may be possible but, if

this is contemplated, Spirax Sarco should be contacted to confirm the suitability

of the product for the application being considered.

ii) Check material suitability, pressure and temperature and their maximum and

minimum values. If the maximum operating limits of the product are lower than

those of the system in which it is being fitted, or if malfunction of the product

could result in a dangerous overpressure or overtemperature occurrence, ensure

a safety device is included in the system to prevent such over-limit situations.

iii) Determine the correct installation situation and direction of fluid flow.

iv) Spirax Sarco products are not intended to withstand external stresses that may

be induced by any system to which they are fitted. It is the responsibility of the

installer to consider these stresses and take adequate precautions to minimise

them.

v) Remove protection covers from all connections before installation.

IM-S21-01 CH Issue 7 3

1.2 Access

Ensure safe access and if necessary a safe working platform (suitably guarded)

before attempting to work on the product. Arrange suitable lifting gear if required.

1.3 Lighting

Ensure adequate lighting, particularly where detailed or intricate work is required.

1.4 Hazardous liquids or gases in the pipeline

Consider what is in the pipeline or what may have been in the pipeline at some

previous time. Consider: flammable materials, substances hazardous to health,

extremes of temperature.

1.5 Hazardous environment around the product

Consider: explosion risk areas, lack of oxygen (e.g. tanks, pits), dangerous gases,

extremes of temperature, hot surfaces, fire hazard (e.g. during welding), excessive

noise, moving machinery.

1.6 The system

Consider the effect on the complete system of the work proposed. Will any proposed

action (e.g. closing isolation valves, electrical isolation) put any other part of the

system or any personnel at risk?

Dangers might include isolation of vents or protective devices or the rendering

ineffective of controls or alarms. Ensure isolation valves are turned on and off in a

gradual way to avoid system shocks.

1.7 Pressure systems

Ensure that any pressure is isolated and safely vented to atmospheric pressure.

Consider double isolation (double block and bleed) and the locking or labelling of

closed valves. Do not assume that the system has depressurised even when the

pressure gauge indicates zero.

1.8 Temperature

Allow time for temperature to normalise after isolation to avoid danger of burns.

1.9 Tools and consumables

Before starting work ensure that you have suitable tools and/or consumables

available. Use only genuine Spirax Sarco replacement parts.

1.10 Protective clothing

Consider whether you and/or others in the vicinity require any protective clothing

to protect against the hazards of, for example, chemicals, high/low temperature,

radiation, noise, falling objects, and dangers to eyes and face.

IM-S21-01 CH Issue 7

1.11 Permits to work

All work must be carried out or be supervised by a suitably competent person.

Installation and operating personnel should be trained in the correct use of the

product according to the Installation and Maintenance Instructions.

Where a formal 'permit to work' system is in force it must be complied with. Where

there is no such system, it is recommended that a responsible person should know what

work is going on and, where necessary, arrange to have an assistant whose

primary responsibility is safety.

Post 'warning notices' if necessary.

1.12 Handling

Manual handling of large and/or heavy products may present a risk of injury. Lifting,

pushing, pulling, carrying or supporting a load by bodily force can cause injury

particularly to the back. You are advised to assess the risks taking into account the

task, the individual, the load and the working environment and use the appropriate

handling method depending on the circumstances of the work being done.

1.13 Residual hazards

In normal use the external surface of the product may be very hot. If used at the

maximum permitted operating conditions the surface temperature of some products

may reach temperatures of 300°C (572°F).

Many products are not self-draining. Take due care when dismantling or removing

the product from an installation (refer to 'Maintenance instructions').

1.14 Freezing

Provision must be made to protect products which are not self-draining against

frost damage in environments where they may be exposed to temperatures below

freezing point.

1.15 Disposal

Unless otherwise stated in the Installation and Maintenance Instructions, this product is

recyclable and no ecological hazard is anticipated with its disposal providing due care is

taken.

1.16 Returning products

Customers and stockists are reminded that under EC Health, Safety and

Environment Law, when returning products to Spirax Sarco they must provide

information on any hazards and the precautions to be taken due to contamination

residues or mechanical damage which may present a health, safety or

environmental risk. This information must be provided in writing including

Health and Safety data sheets relating to any substances identified as hazardous

or potentially hazardous.

IM-S21-01 CH Issue 7 5

2. Technical details

See the following Technical Information Sheets, for full details of: Materials, sizes and

pipe connections, dimensions, weights, operating ranges, capacities and spare parts.

SA control valve TI reference

BM, BMRA, BMF and BMFRA TI-P036-01

BX, BXRA TI-P036-02

SB, SBRA TI-P044-01

NS, NSRA TI-P049-01

KX31, KX33, KY31 and KY33 TI-P078-01

KA31, KA33, KB31, KB33 and KC31 TI-P078-02

KX51 and KY51 TI-P078-03

KA51, KB51 and KC51 TI-P078-04

KX43 and KY43 TI-P078-05

KA43, KB43 and KC43 TI-P078-06

KA61, KA63 and KC63 TI-P078-08

Copies of the above are available on request.

IM-S21-01 CH Issue 7

3. Installation and commissioning

Note: Before actioning any installation observe the 'Safety information' in Section 1.

Important note

The valves covered by these instructions are for use with Spirax Sarco EL and SA control

systems Types 121, 122, 123 and 128. (The Types 122 and 128 SA control system are not

suitable for valves above 1" /DN25).

3.1 General installation

The valve should always be fitted in a horizontal pipeline with the flow in the direction indicated

by the arrow marked on the body with the sensor in a vertical plane below the pipeline as shown

in Figure 1 (SA control system). Valves should be mounted in the pipeline in accordance with

the actuator Installation and Maintenance Instructions.

A suitable strainer should always be fitted upstream of the valve. Additionally on steam

installations a separator should be fitted before the valve, plus a steam trap set on applications

where condensate may accumulate upstream of the valve.

Warning:

The SA control system actuator must be securely connected to the valve via the

screwed connection on the bottom of the valve and the half union coupling on the actuator

before any fluid is allowed to pass through the valve.

Similarly, the actuator should not be disconnected from the valve until the valve itself is

fully isolated.

It is important that line stresses i.e. expansion or inadequate supporting of the pipe are not

imposed on the valve body.

If the valve is properly sized for the duty it has to perform it will often be smaller than the

pipeline. This is particularly so where the medium passing through the valve is steam, in which

case any reduction in line size should be made using eccentric reducers. The piping on both

upstream and downstream sides of the valve must be of ample size to avoid undue pressure

drop in the line and any reduction to meet the size of the valve should be made close to the

valves as shown in Figure 1.

It is advisable to protect the valve by fitting a strainer on the upstream side. By fitting the strainer

on its side where the medium is steam you will prevent the body filling with water which would

reduce the screening area.

In most steam installations, water formed by condensation due to radiation losses will be

present in the upstream pipeline and should be removed by an adequate drain point and trap,

as shown in Figure 1.

3.2 Bypass arrangements

It is recommended that isolating valves be fitted upstream and downstream of the control

valve together with a manual regulating valve to bypass the group (see the dotted pipework,

Figure 1). The process may then be controlled by the bypass valve while the control valve is

isolated for maintenance purposes.

3.3 Commissioning

For commissioning instructions refer to the Operation, Installation and Maintenance Instructions,

covering Spirax Sarco control systems.

IM-S21-01 CH Issue 7 7

SA control

system actuator

When medium is steam fit

a trap set to the drain line.

control

valve

Pipeline

strainer

Fig. 1 Typical installation showing recommended bypass

Steam

Condensate

Isolating

valve

Isolating

valve

Eccentric reducers

Bypass

Manual

regulating

valve

IM-S21-01 CH Issue 7

Fig. 4

KX (DN15 - 25)

Optional

extra

bleed

Optional

extra

bleed

Fig. 3 SBRA

Fig. 5

KX and KY (DN32 - 50)

Strainer BMRA or

BXRA valve

Small bore

bypass

Fig. 2

Typical bypass

arrangement for

the BMRA and

BXRA valves

3.5 Permanent bleed

BMRA and BXRA valves are normally closed. When used as a cooling control it may be

necessary to create a permanent flow over the sensor. In this case this can be achieved by

installing a small bore bypass around the valve as shown in Figure 2. A 6 mm line will usually

be adequate with the manual valve about one turn open.

SBRA (Figure 3) and KX (DN15 - 25) (Figure 4) valves are available with or without bleed. When

used as a cooling control with the sensor fitted in the cooling liquid line a valve having a bleed

would be required. This bleed hole is now fixed. In other cases, a non bleed valve should be

installed.

With KX and KY valves (DN32 - 50) (Figure 5) again models are available with or without bleed.

Valves with a bleed arrangement have a 3 mm hole between the inlet and outlet. This permanent

bleed arrangement can be sealed by tapping the hole and sealing it off with a 4BA or M4 screw

before the valve is installed.

Optional

extra

bleed

IM-S21-01 CH Issue 7 9

4. Maintenance

Note: Before actioning any maintenance programme observe the

'Safety information' in Section 1.

Warning

The metal foil sheet used to reinforce gaskets is very thin and sharp. Care should be

taken when handling to avoid the possibility of cuts or lacerations to fingers or hands.

4.1 Routine maintenance procedures

24 hours operation

After 24 hours service check pipework connections and flange bolts for tightness.

Annually

The valve should be inspected for wear and tear replacing any worn or damaged parts such as

valve plug and stem, valve seat.

4.2 General maintenance information:

- The valve faces must be kept clean.

- The strainer should be cleaned at regular intervals to ensure that the flow to the valve is clean

and unrestricted.

- If at any time it is necessary to take the valve out of the line for servicing then the appropriate

safety precautions need to be adhered to (see Section 1).

- The available spares and fitting instructions are detailed on the appropriate Technical

Information Sheet (see Section 2).

4.3 KB and KC valves (refer to Figure 6)

With the bellows assembly it is essential that the central passage 'X' through the valve push rod

and the ports 'Y' are kept clear. To facilitate cleaning (should this become necessary) the end

of the passage is blanked by a 4 mm 'Unbrako' set screw 'Z' which can be removed to enable

a piece of wire to be passed through the passage and ports.

It is important that the set screw 'Z' is replaced before the valve is put back into service.

Fig. 6

IM-S21-01 CH Issue 7

Valve

stem

Fusible

device

Fig. 7 Fig. 8

4.4 SBRA valve with fusible device (refer to Figures 7 and 8)

Replacing or resetting the fuse:

- Isolate the valve and unscrew the bonnet (see Figure 7).

- Unscrew the retaining nut and withdraw the valve, valve stem, fuse and spring assembly.

- The fuse may now be unscrewed from the valve stem and the new one fitted (see Figure 8).

Alternatively the existing fuse may be reset after dismantling as above, by immersing it in hot

water at a temperature above its fusing point 80°C (176°F) on the standard fuse.

When the fuse solder head reaches a fluid state the two cylinders can be pushed together until

the ends are flush. Allow to cool and refit.

4.5 KA61, KA63 and KC63 valves (refer to Figure 9)

Firstly remove the control system sensor from the plant and allow to cool.

SA controls:

- Disconnect the actuator from the valve.

- Before attempting to carry out any repairs, make sure that the valve is fully isolated.

- It is important to always renew the complete assembly as listed above and to make sure that

all of the joint faces are clean.

How to replace the valve seat assembly

Remove the bonnet assembly and unscrew the head/bellows assembly X from the bonnet.

KC63:

- The complete head / bellows assembly can now be withdrawn and a new assembly fitted.

KA63 and KC63:

- Remove the circlip C, washer U, head A and seal B and refit the parts in reverse order

ensuring that the circlip is correctly located in the groove.

KA61:

- The complete head A can now be withdrawn and a new assembly fitted.

- Unscrew the valve seat D and replace with a new seat ring and seat gasket.

- Lightly coat all the gaskets with a suitable jointing compound before fitting.

- Refit the bonnet assembly using new gaskets, taking care to tighten the bonnet nuts evenly.

Valve

stem

Bonnet

Retaining nut

Fusible

device

Fig. 9

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