GESTRA

GESTRA Steam Systems

UNA 23 UNA 25 UNA 26

Installation Instructions 810516-05
Steam Traps UNA 23, UNA 25, UNA 26

Contents
Page Important Notes Usage for the intended purpose .............................................................................................................. 7 Safety note ............................................................................................................................................. 7 Danger ................................................................................................................................................... 7 Ratings pursuant to article 9 of the PED ................................................................................................. 7 Explanatory Notes Scope of supply ...................................................................................................................................... 8 Description ............................................................................................................................................. 8 Function ................................................................................................................................................. 8 Technical data ................................................................................................................................. 9, 10 Corrosion resistance ............................................................................................................................ 10 Sizing ................................................................................................................................................... 10 Name plate / marking ........................................................................................................................... 10 Installation UNA 23, 25, 26 .................................................................................................................................... 11 Heat treatment of welds ....................................................................................................................... 12 Hand vent valve .................................................................................................................................... 12 Commissioning UNA 23, 25, 26 .................................................................................................................................... 12 Operation Hand vent valve .................................................................................................................................... 12 Float lifting lever .................................................................................................................................. 12 Maintenance Check steam trap ................................................................................................................................. 13 Clean / exchange control unit ................................................................................................................ 13 Clean / exchange sightglass cover ........................................................................................................ 14 Torques ................................................................................................................................................ 15 Spare Parts Spare parts list ............................................................................................................................... 16, 17 Annex Declaration of conformity ..................................................................................................................... 18 2

Capacity Chart
[lb/h] 20 000 15 000 10 000 8000 6000 5000 4000 3000 2000 1000 800 600 500 400 300 200 [kg/h] Orifice AO 4 4 7000 6000 5000 4000 3000 2000 Orifice 32 AO 13 Orifice 13

3 4 5 6

0 !

QC [kg/h] QH [kg/h] x F

1000 800 600 500 400 300 200

100 0.1 1 2 0.2 3 4 0.3 0.4 0.6 0.8 1 6 8 10 20 2 3 4 6 8 10 200 20 32 bar

PMX 1

30 40

60 80100

300 465 psi

Factor F

1.1

1.18

1.2

1.3

1.4

1.48 1.53

1 2 3 4 5 5
Fig. 1

Orifice 2, DN 40 + 50 mm (1 + 2") Orifice 4, DN 40 + 50 mm (1 + 2") Orifice 8, DN 40 + 50 mm (1 + 2") Orifice 13, DN 40 + 50 mm (1 + 2") Orifice 22, DN 40 + 50 mm (1 + 2") Orifice 2, DN 15 25 mm ( 1")

6 7 8 9 0 !

Orifice 32, DN 40 + 50 mm (1 + 2") Orifice 4, DN 15 25 mm ( 1") Orifice 8, DN 15 25 mm ( 1") Orifice 13, DN 15 25 mm ( 1") Orifice 22, DN 15 25 mm ( 1") Orifice 32, DN 15 25 mm ( 1")

Dimensions A B C D E F G O N M L F K J

H F F I

Fig. 2

Parts Drawings P B O

Fig. 3

V T U
Fig. 4

T S
5

Key A B C D E F G H I J K L M N O P Q R S T U V
Hexagon-socket screw Name plate Control unit Simplex Body gasket (graphite/CrNi) Hand vent valve Gasket 17 x 23 Control unit Duplex Plug 3/8" BSP Float lifting lever with handle Cover Hexagon-socket screw Orifice Seat gasket (graphite/CrNi) Deflector Body Hexagon nut Fixing stud Hexagon-socket screw Flange for sightglass cover Gasket (graphite/CrNi) Water-level gauge glass Sightglass cover

Important Notes
Usage for the intended purpose Use steam trap type UNA 23 / UNA 25 / UNA 26 only for the discharge of condensate within the admissible pressure/temperature ratings. Contact the factory for specific recommendations concerning the chemical resistance and suitability of the valve material for the application in question. Safety note The equipment may only be installed by qualified staff. Qualified staff are those persons who through adequate training in engineering, the use and application of equipment in accordance with regulations concerning steam systems, and first aid & accident prevention have achieved a recognised level of competence appropriate to the installation and commissioning of this device. Danger The steam trap is under pressure when the system is operating. When loosening flanged connections or plugs hot water or steam might escape. This presents the danger of severe scalding. Before carrying out any installation or maintenance work it is therefore essential to isolate and depressurize the trap. The trap is hot during operation. This presents the danger of severe burns. Before carrying out any installation or maintenance work make sure that the trap is cold. Sharp-edged internals might cut your hands. Wear protective gloves when replacing internals. Ratings pursuant to article 9 of the PED1)
Fluid Fluid group Use 1 no gas 2 yes 1 no liquid 2 yes I 40 50 yes UNA 25/26
Exception pursuant to article 3.3

Category Nominal size DN CE marking Type

1)

Exception pursuant Exception pursuant to article 3.3 to article 3.3

15 25 no all

40 50 no UNA 23

40 50 no UNA 26 H
Flange Class 150

PED = Pressure Equipment Directive

Explanatory Notes
Scope of supply UNA 23 1 Steam trap UNA 23 1 Installation manual UNA 25 1 Steam trap UNA 25 1 Installation manual UNA 26 1 Steam trap UNA 26 1 Installation manual Description UNA 23, UNA 25 and UNA 26 are ball float traps with rolling ball closing mechanisms. The steam traps work independently of back pressure, thus ensuring universal application. UNA 23/UNA 25/ UNA 26 features a body with bolted cover and a control unit. Two different control units are available: Level-dependent SIMPLEX control for cold condensate and temperaturedependent DUPLEX control with automatic deaeration for saturated steam systems. Optional item: sightglass cover with integral water-level gauge glass (UNA 23, PN 16).
suitable for large condensate flowrates asbestos-free body gasket (graphite / CrNi) horizontal or vertical installation (dependent on body design)

UNA 2 . . . with Simplex control 1 Hand vent valve with gasket Design with float lifting lever Float lifting lever installed 1 Lever extension

Function The ball valve of the control unit is operated by the float as a function of the condensate level in the trap. The cross-sectional area (CSA) of the orifice dictates the max. flowrate when the valve is completely open. The max. admissible differential pressure of the control unit is a function of the CSA of the orifice and the density of the fluid to be discharged. There are six different closing units (orifices) available which can also be exchanged subsequently. Float traps equipped with control units DUPLEX enable automatic temperature-dependent deaeration of saturated steam systems during start-up and in continuous operation.

Explanatory Notes
Technical Data

continued

Orifices (O)
O 2 O 4 O 8 O 13 O 22 O 32
1) 2)

Max. admissible differential pressure 1) 2) PMX [bar] 2 bar ( 30 psi) 4 bar ( 60 psi) 8 bar (115 psi) 13 bar (185 psi) 22 bar (320 psi) 32 bar (465 psi)

UNA 23 X X X X

UNA 25, UNA 26 X X X X X X

Observe pressure/temp. specifications. Inlet pressure minus outlet pressure.

Pressure/Temperature Ratings*) UNA 23 H / V, PN 16

Body material Nominal sizes (DN) End connections Max. service pressure PMA Related temperature TMA Gey cast iron EN-JL 1040 (GG-25) 15, 20, 25, 40, 50 mm Flanged to EN 1092-2, form B 16 (230 psig) 11.2 (163 psig) 9.6 (140 psig) 120 (248 F) 250 (482 F) 300 (572 F)

[barg] [C]

Pressure/Temperature Ratings*) UNA 25 H / V, PN 40

Body material Nominal sizes (DN) End connections Max. service pressure PMA Related temperature TMA S.G. (ductile) iron EN-JS 1025 (GGG-40.3) 15, 20, 25, 40, 50 mm Flanged to DIN PN 40 38 (550 psig) 32 (465 psig) 25 (360 psig) 120 (248 F) 250 (482 F) 300 (572 F)

[barg] [C]

Pressure/Temperature Ratings*) UNA 26 H, PN 40

Body material Nominal sizes (DN) End connections Cast steel 1.0460 (C 22.8) / ASTM A 105 15, 20, 25 mm Flanged to DIN PN 40, ASME Class 300 Screwed BSP or NPT Butt-weld, socket weld 40 (580 psig) 32 (465 psig) 21 (305 psig) 120 (248 F) 250 (482 F) 400 (752 F)

Max. service pressure PMA Related temperature TMA

[barg] [C]

Pressure/Temperature Ratings*) UNA 26 H, PN 40

Body material Nominal sizes (DN) End connections Cast steel 1.0619 (GS-C 25) 40, 50 mm Flanged to DIN PN 40, ASME Class 300 Screwed BSP or NPT Butt-weld, socket weld 33 (479 psig) 26 (377 psig) 21 (305 psig) 120 (248 F) 250 (482 F) 400 (752 F)

Max. service pressure PMA Related temperature TMA

[barg] [C]

*) When used for the intended purpose.

Explanatory Notes
Technical Data
continued

continued

Pressure/Temperature Ratings*) UNA 26 H , Flanged to Class 150

Body material Nominal sizes (DN) End connections Max. service pressure PMA Related temperature TMA Cast steel 1.0460 (C 22.8) / ASTM A 105 DN 15, 20, 25 1.0619 (GS-C 25) DN 40, 50 15, 20, 25, 40, 50 mm Flanged to ASME Class 150 16.9 (247 psig) 12.1 (174 psig) 6.5 (94.3 psig) 120 (248 F) 250 (482 F) 400 (752 F)

[barg] [C]

Pressure/Temperature Ratings*) UNA 26 V, PN 40

Body material Nominal sizes (DN) End connections Max. service pressure PMA Related temperature TMA Cast steel 1.0619 (GS-C 25) 15, 20, 25, 40, 50 mm Flanged to DIN PN 40 26 (377 psig) 250 (482 F)

[barg] [C]

33 (479 psig) 120 (248 F)

21 (305 psig) 400 (752 F)

*) When used for the intended purpose.

Corrosion Resistance When used for its intended purpose the safe functioning of the steam trap will not be impaired by corrosion. Sizing The trap body must not be subjected to sharp increases in pressure. Welds and flanges of the trap are designed to withstand dynamic loading (bending and alternative stress). The dimensional allowances for corrosion reflect the latest state of technology. Name Plate / Marking Design specifications and ratings according to EN 19 and EN ISO 26652 are indicated on the name plate and trap body / cover.
Design

UNA 2 . . . h: UNA 2 . . . v:

for horizontal lines for vertical lines Type of control unit (cf. Description) with Perbunan ball (max. 40 C) with inner vent tube Type of orifice

SIMPLEX / DUPLEX:

additional P: additional R:
Orifice:

4 Stamp on name plate, e. g. 00 specifies the manufacturing year and the quarter,

in this case the 4th quarter in 2000.

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Installation
UNA 23, UNA 25, UNA 26 The float traps can depending on their body design be installed in horizontal or vertical pipelines with downward flow. Flanged Traps 1. 2. 3. 4. 5. Take care of correct position of installation. Name plate B must always be on top. Take care of flow direction. The flow arrow is on the trap body. Remove plastic plugs. They are only used as transit protection. Clean seating surfaces of both flanges. Install steam trap.

Screwed-Socket Traps 1. 2. 3. 4. 5. Take care of correct position of installation. Name plate B must always be on top. Take care of flow direction. The flow arrow is on the trap body. Remove plastic plugs. They are only used as transit protection. Clean threads of screwed sockets. Install steam trap.

Socket-Weld Traps 1. 2. 3. 4. 5. Take care of correct position of installation. Name plate B must always be on top. Take care of flow direction. The flow arrow is on the trap body. Remove plastic plugs. They are only used as transit protection. Clean socket-weld ends. Arc-weld trap only manually (welding process 111 and 141 in accordance with DIN EN 24063).

Butt-Weld Traps 1 2. 3. 4. 5. Take care of correct position of installation. Name plate B must always be on top. Take care of flow direction. The flow arrow is on the trap body. Remove plastic plugs. They are only used as transit protection. Clean butt-weld ends. Arc-weld trap only manually (welding process 111 and 141 in accordance with DIN EN 24063) or use gas-welding process (welding process 3 in accordance with DIN EN 24063).

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Installation

continued

Attention
Only qualified welders certified e. g. according to DIN EN 287 may weld the steam trap

into pressurized lines. Heat treatment of welds A subsequent heat treatment of the welds is not required. Hand vent valve 1. Remove plug H. 2. Insert gasket F, fit hand vent valve E in place and tighten with a torque of 75 Nm. 3. Close the hand vent valve. Tools
Spanner A.F. 17 mm to DIN 3113, form B Torque spanner 20 120 Nm, to DIN ISO 6789

Commissioning
Before commissioning make sure that the hand vent valve and the float-lifting lever are firmly attached to the trap and do not leak.

Operation
Hand vent valve 1. Take heed of the note Danger on page 7. 2. Open the hand vent valve if necessary. 3. Close hand vent valve firmly after the venting process. Float lifting lever 1. 2. 3. 4. Take heed of the note Danger on page 7. Attach handle to float-lifting lever I, Fig. 2. Turn float-lifting lever I according to the direction arrow on the cover J. Turn float-lifting lever I in the opposite direction of the arrow to close the valve and remove the handle.

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Maintenance
GESTRA steam traps type UNA 2... do not require any special maintenance. However, if used in new installations which have not been rinsed it may be necessary to check and clean the trap. Check steam trap You can check the trap UNA 2... for steam loss during operation using the ultrasonic measuring unit VAPOPHONE or the test unit TRAPtest . In case of steam loss clean the trap and/or replace the control unit or orifice (closing unit). Clean /exchange control unit 1. 2. 3. 4. 5. 6. Take heed of the note Danger on page 7. Undo the body screws A or hexagon nuts P. Remove cover J from body O. Unscrew hexagon-socket screws K, remove control unit C or G and orifice L. Replace control unit C or G and orifice L in case of visible signs of wear or damage. Clean body, internals and all gasket surfaces. Apply heat-resistant lubricant to all threads and the seating surfaces of the closing unit and cover (use for instance WINIX 2150). 7. Insert orifice L, attach control unit C or G and tighten screws K alternately with a torque of 10 Nm (DN 40 and 50 mm) or 5 Nm (DN 15 25 mm). 8. Insert a new body gasket D. 9. Put cover onto the body. Tighten body screws A or hexagon nuts P alternately in several steps to the torque indicated in the table on page 15. Tools
Spanner A. F. 17, 19, 22 and 24 mm to DIN 3113, form B. Allen key A. F. 5, 6, 10 mm to ISO 2936 Torque spanner 10 60 Nm, 60 120 Nm; DIN ISO 6789

WINIX 2150 is a registered trademark of WINIX GmbH, Norderstedt

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Maintenance continued
Clean / exchange sightglass cover 1. 2. 3. 4. 5. 6. Take heed of note Danger on page 7. Undo hexagon-socket screws R. Remove flange S from body V. Remove and clean water-level gauge glass U. Replace water-level gauge glass U and gaskets T in case of visible signs of wear or damage. Clean all gasket surfaces. Apply heat-resistant lubricant to all threads and seating surfaces of the flange (use for instance WINIX 2150). 7. Insert gasket T and water-level gauge glass U. Install flange S and tighten the screws R alternately with a torque of 15 Nm. Attention Do not change the factory setting of the bellows (thermostatic element). In case of inadvertent misadjustment restore the factory setting. When the float ball is pushed right down the dimension 1 (length of bellows) should be as follows: DN 15 25 mm ( 1") control unit up to 13 bar 1 = 34.5 mm DN 15 25 mm ( 1") control unit up to 32 bar 1 = 32 mm DN 40 + 50 mm (1 + 2"), 1 = 51.5 mm

WINIX 2150 is a registered trademark of WINIX GmbH, Norderstedt

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Torques

Item

Steam trap UNA 23, UNA 25, UNA 26, DN 15 50 ( 2") UNA 23 with sightglass cover, DN 15 50 ( 2") UNA 23, UNA 25, UNA 26, DN 15 25 ( 1") UNA 23, UNA 25, UNA 26, DN 25 + 40 (1 + 1") UNA 23 h, DN 15 25 ( 1") UNA 23, DN 40 + 50 (1 + 2") UNA 25, UNA 26, DN 15 25 ( 1") UNA 25, UNA 26, DN 40 + 50 (1 + 2")

Torque [Nm] 75 15 5 10 40 75 60 115

E H I R K K A P P P

All torques indicated in the table are based at a room temperature of 20 C. Apply heat-resistant lubricant, e. g. WINIX 2150, to threads.

WINIX 2150 is a registered trademark of WINIX GmbH, Norderstedt

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Spare Parts
Spare part list
Ref. no. Ref. no. DN 40 + 50 (1+2") 560 492 560 486 560 488 560 480 560 490 560 093 560 092 560 091 560 090 560 089 560 088 560 087 560 086 560 085 560 084 560 083 560 082

Item

Designation

DN 15 25 ( 1") 560 491 560 486 560 487 560 481 560 489 Orifice 32 Orifice 22 Orifice 13 Orifice 8 Orifice 4 Orifice 2 560 078 560 077 560 076 560 075 560 074 560 073 560 072 560 071 560 070 560 069 560 068 560 067

D F T U T M G L M K D

Body gasket*) (graphite/CrNi) Gasket*) C 17 x 23 mm Sightglass gasket**) (graphite/CrNi) Reflection sightglass with gasket Seat gasket*) (graphite/CrNi) Control unit Duplex, complete

C L M K D

Control unit Simplex, complete

Orifice 32 Orifice 22 Orifice 13 Orifice 8 Orifice 4 Orifice 2

*) Minimum order quantity 20 items. **) Minimum order quantity 10 items. Contact your local dealer for smaller quantities.

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Spare Parts
Spare part list

continued

Ref. no.

Ref. no. DN 40 + 50 (1+2") 560 094

Item

Designation

DN 15 25 ( 1") 560 079

C M K D G M K D G M K D L M K

Control unit Simplex, complete without orifice

Control unit Duplex up to 13 bar, complete without orifice

560 080

560 095

Control unit Duplex above 13 bar, complete without orifice

560 081

560 096

Orifice, complete without control unit

Orifice 32 Orifice 22 Orifice 13 Orifice 8 Orifice 4 Orifice 2

560 045 560 044 560 043 560 042 560 041 560 040 560 058

560 051 560 050 560 049 560 048 560 047 560 046

E F

Hand vent valve with gasket

*) Minimum order quantity 20 items. Contact your local dealer for smaller quantities.

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Annex
Declaration of Conformity We hereby declare that the pressure equipment UNA 25 and UNA 26, nominal sizes DN 40 50 mm, conform to the following European Directive:
EC Pressure Equipment Directive (PED) No. 97/23 of 29 May 1997

These steam traps are pressure equipment as defined in article 1, section 2.1.4 of the PED. Applied conformity assessment procedure acc. to Annex III: module A. This declaration is no longer valid if modifications are made to the equipment without prior consultation with us.
Bremen, 27th November 2000 GESTRA AG

Head of Design Dept. Uwe Bledschun

(Academically qualified engineer)

Quality Assurance Representative Walter Meyer

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For your notes

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GESTRA

Agencies all over the world

www.gestra.de
Espaa
GESTRA ESPAOLA S.A. Luis Cabrera, 86-88 E-28002 Madrid Tel. 00 34 91 / 51 52 032 Fax 00 34 91 / 41 36 747; 51 52 036 E-mail: aromero@flowserve.com

Polska
GESTRA POLONIA Spolka z.o.o. Ul. Schuberta 104 PL - 80-172 Gdansk Tel. 00 48 58 /306 10 -02 od 10 Fax 00 48 58 /306 33 00 E-mail: gestra@gestra.pl

Great Britain
Flowserve Flow Control (UK) Ltd. Burrel Road, Haywards Heath West Sussex RH 16 1TL Tel. 00 44 14 44 / 31 44 00 Fax 00 44 14 44 / 31 45 57 E-mail: gestraukinfo@flowserve.com

Portugal
Flowserve Portuguesa, Lda. Av. Dr. Antunes Guimares, 1159 Porto 4100-082 Tel. 0 03 51 22 / 6 19 87 70 Fax 0 03 51 22 / 6 10 75 75 E-mail: jtavares@flowserve.com

Italia
Flowserve S.p.A. Flow Control Division Via Prealpi, 30 l-20032 Cormano (MI) Tel. 00 39 02 / 66 32 51 Fax 00 39 02 / 66 32 55 60 E-mail: infoitaly@flowserve.com

USA
Flowserve DALCO Steam Products 2601 Grassland Drive Louisville, KY 40299 Tel.: 00 15 02 / 4 95 01 54, 4 95 17 88 Fax: 00 15 02 / 4 95 16 08 E-Mail: dgoodwin@flowserve.com

GESTRA AG
P. O. Box 10 54 60, D-28054 Bremen Mnchener Str. 77, D-28215 Bremen Telephone +49 (0) 421 35 03 - 0 Fax +49 (0) 421 35 03 - 393 E-Mail gestra.ag@flowserve.com Internet www.gestra.de
810516-05/604cm 1998 GESTRA AG Bremen Printed in Germany

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