Spirax Sarco DP27S User manual

IM-IBR16-27IN Issue 6 1

1. Safety information

2. General

product information

3. Installation

4. Commissioning

5. Maintenance

6. Spare parts

7.Faultnding

Printed in India

DP27S and DP27SY

Pilot Operated Pressure Reducing Valves

Installation and Maintenance Instructions

IM-IBR16-27IN

Issue 6

IM-IBR16-27IN Issue 6

1. Safety information

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

installed, commissioned, used and maintained by qualied 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.

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 Indian Boiler

Regulations, 1950.

i) The products have been specically designed for use on steam and air. The

product s’ use on oth er ui d s m ay be possible but, if this is contem p lated, Spirax

Sarco should be contacted to conrm the suitability of the product for the

application being considered.

i i ) C h e c k m a t e r i a l s u i t a b i l i t y , p r e s s u r e a n d t e m p e r a t u r e a n d t h e i r m a x i m u m a n d

m i n i m u m v a l u e s . I f t h e m a x i m u m o p e r a t i n g l i m i t s o f t h e p r o d u c t a r e l o w e r t h a n

those of the system in which it is being tted, 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 uid ow.

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

be induced by any system to which they are tted. 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 and protective lm from all

name-plates, where appropriate, before installation on steam or other high

temperature applications.

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

p r e v i o u s t i m e . C o n s i d e r :  a m m a b l e m a t e r i a l s , s u b s t a n c e s h a z a r d o u s t o h e a l t h ,

extremes of temperature.

IM-IBR16-27IN Issue 6 3

1.5 Hazardous environment around the product

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

e x t r e m e s o f t e m p e r a t u r e , h o t s u r f a c e s ,  r e h a z a r d ( e . g . d u r i n g w e l d i n g ) , e x c e s s i v e

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.

C o n s i d e r d o u b l e i s o l a t i o n ( d o u b l e b l o c k a n d b l e e d ) a n d t h e l o c k i n g o r l a b e l l i n g

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.

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.

IM-IBR16-27IN Issue 6

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 232°C.

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. However, if the valve has any PTFE components,

special care must be taken to avoid potential health hazards associated with

decomposition/burning of this material.

PTFE:

- Can only be disposed of by approved methods, not inceration.

- Keep PTFE waste in a separate container, do not mix it with other rubbish, and

consign it to a landll site.

IM-IBR16-27IN Issue 6 5

2.2 Sizes and pipe connections

Screwed BSP or NPT (DN15, DN20 and DN25 only).

Flanged DN15LC - Low Capacity version, DN15, DN20, DN25, DN32, DN40 and DN50.

DN15 - DN50 ASME 150

Standard flanges: DN15 ASME 300

DN25 - DN50 ASME 300

2. General product information

2.1 General description

These instructions apply to the DP27S and the derivative DP27SY.

The instructions primarily relate to the use of the DP27S on steam but can be used as a

guide when the valve is used on compressed air.

Note: For additional information see the relevant Technical Information Sheets.

IM-IBR16-27IN Issue 6

2.3 Pressure / temperature limits

The product must not be used in this region.

For optimum performance, the maximum design pressure should not exceed 17.2 bar g

A-D-C Screwed and flanged ASME 300

A-B-C Flanged ASME 150.

Note: DP27S has a variable rate conical pressure adjustable spring fitted providing a

downstream pressure range of 0.2 - 17 bar g.

DP27SY has a pressure spring with a range of 0.2 - 3 bar g.

Body design conditions PN25

Maximum design pressure 17.2 bar g @ 232°C

Maximum design temperature 232°C @ 17.2 bar g

Minimum design temperature -10°C

Maximum upstream pressure for saturated steam service 17 bar g

Maximum operating temperature 232°C

Minimum operating temperature 0°C

Note: For lower operating temperatures consult Spirax Sarco.

Maximum differential pressure 17 bar

Designed for a maximum cold hydraulic test pressure of: 25.8 bar g



   













Pressure bar g

Temperature °C

Steam

saturation

curve

IM-IBR16-27IN Issue 6 7

Note: Before actioning any maintenance programme for the pilot operated

pressure reducing valve (PRV) observe the 'Safety information' in Section 1.

Referring to these Installation and Maintenance Instructions,

name-plate and Technical Information Sheet, check that the product is suitable for the

intended installation.

3.1 Supply

DP27S (Figure 1)

These are supplied ready for fitting and have a variable rate conical pressure spring suitable

for a downstream pressure of 0.2 - 17 bar.

DP27SY (Figure 1)

The DP27SY is supplied as the DP27S, but has a lower rate pressure adjustment spring for

a downstream pressure range of 0.2 - 3 bar.

Pressure adjustment spring

Downstream internal

pressure balance pipe

Pressure setting adjustment screw

Lock-nut

Recommended downstream pressure

balance pipe connection

(refer to Section 3.8, page 10)

Fig. 1

3. Installation

IM-IBR16-27IN Issue 6

Pressure

sensing

pipe

Small bore

drain

Strainer with

100 mesh stainless

steel screen

Separator

Steam

supply Spiratec

sensor

chamber

Float type

steam trap

Pressure

reducing

valve

DP27S

0.9 m or

15 pipe diameters clear

on either side

See Section 3.6, page 9

Downstream isolating valve to

provide no-load conditions for

setting pressure reducing valve

Safety

valve

Discharge

pipe

Isolation

valve

Strainer

3.2 Fitting (Figures. 2, 3 and 4)

The valve should always be fitted in a horizontal pipeline with the main diaphragm

chamber below the line (Figure 2). To meet high capacities or widely varying loads, or

where stand-by facility is required, two or more valves may be used in parallel (Figure 3).

For pressure turndown in excess of 10 to 1 consideration should be given to using the two

valves in series. To avoid instability pipework volume between the valves should be equivalent

to at least 50 pipe diameters in length of the intermediate correctly sized pipework. To

ensure adequate drainage of the space between the two reducing valves a trap set should

be fitted as shown in Figure 4.

Separator

Compressed

air

Fig. 2 Recommended installation

Installation for

compressed air Compressed

air trap

Float type

steam trap

Alternative for

draining

separator

Strainer Sight

glass

Isolation

valve

IM-IBR16-27IN Issue 6 9

Fig. 3 Two pressure reducing valves in parallel

Steam

supply

Q See Section 3.6

3.3 Pipeline sizing

The piping on both sides of the valve must be sized so that velocities do not exceed 30 m / s.

This means that a properly sized valve will often be smaller than the connecting

pipework.

3.4 Pipeline stresses

Line stresses caused by expansion or inadequate support should not be imposed on the

valve body.

3.5 Isolating valves

These should preferably be of the full bore type.

3.6 Removal of condensate

It is recommended that a separator with trap set is fitted upstream of the valve to ensure

dry steam conditions.

If there is a rise in the low pressure line from the valve then a further drain point should

be provided to keep the valve drained after shutdown.

Steam supply

Q See Section 3.6

Fig. 4 Two pressure reducing valves installed in series

Q

Separator

Trap set Trap set

IM-IBR16-27IN Issue 6

3.7 Protection from dirt

The valve should be protected by a pipeline strainer with 100 mesh screen. The strainer

should be fitted on its side to prevent the accumulation of water. The strainer screen should

be examined and cleaned at regular intervals.

3.8 Pressure sensing

For applications that require closer control, improved stability or maximum capacity condition

the internal balance pipe should be replaced by an external pressure sensing pipe

(supplied by others) as follows:

Remove the internal balance pipe assembly.

The resulting " BSP tapping in the side of the body should be blanked using the plug provided

in the linen bag attached to the valve (which also contains the fitting instructions). The other

" BSP tapping in the side of the pilot valve chamber, should be used to fit the external

pressure sensing pipe. This is suitable for the fitting of 6 mm O/D pipe. If suitable pipe is not

available the compression fitting can be removed and ¼" nominal bore steel pipe screwed

directly into the pilot valve chamber.

The pressure sensing pipe should be connected into the top of the reduced pressure main

at a point where in either direction there is a length of straight pipe uninterrupted by fittings

for at least 1 m or 15 pipe diameters whichever is the greater. It should be arranged with a

positive fall so that any condensate can drain away from the DP27S. Where the size of the

reduced pressure main makes it difficult to maintain a fall when entering the top of the main,

the pressure sensing pipe may be connected in the side of the main.

3.9 Pressure gauges

It is essential to fit a pressure gauge on the upstream and downstream side so that the

valve can be properly set and monitored.

3.10 Continuous duty

For continuous duty applications where a constant steam supply is essential then a parallel

stand-by PRV station is recommended to allow for planned maintenance, see Figure 3,

page 9. Alternatively a bypass line can be used (see Figure 6, page 12). It is important that the

bypass should have a similar capacity to the pressure reducing valve which is achieved by

choosing an appropriately sized valve or by using a reduced orifice in the line.

The handwheel should be padlocked to prevent unauthorised use, and when in use should

be under constant manual supervision.

The bypass may be arranged above or to the side of the main assembly but never below it.

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