Spirax Sarco DP17 Bedienungsanleitung

IM-P100-05 CTLS Issue 17

1. Safety information

2. General product

information

3. Installation

4. Commissioning

5. Maintenance

6. Spare parts

7. Fault finding

1000026/16

DP17, DP17E, DP17G, DP17R, DP17Y and DP27G

Pilot Operated Pressure Reducing Valves

Installation and Maintenance Instructions

Printed in GB

IM-P100-05

CTLS Issue 17

IM-P100-05 CTLS Issue 17

1. 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.

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 Pressure Equipment

Directive (PED)and carry the mark when so required. The products fall within

the following Pressure Equipment Directive categories:

Product Group 2

Gases

DP17, DP17E, DP17G DN15 - DN40 SEP

DP17R, DP17Y and DP27G DN50 1

i) The products have been specifically designed for use on steam, air and inert

industrial gases which are in Group 2 of the above mentioned Pressure Equipment

Directive.

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 and protective film 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

IM-P100-05 CTLS Issue 17

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.

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,

IM-P100-05 CTLS Issue 17

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. 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 landfill site.

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-P100-05 CTLS Issue 17

2. General product information

2.1 General description

These instructions apply to the DP17 and most derivatives including the DP17E, DP17G,

DP17R, DP17Y and DP27G.

The instructions primarily relate to the use of the DP17 on steam but can be used as a guide

when the valve is used on compressed air.

For compressed air the DP17G and DP27G are recommended which have a nitrile seal for

both the main valve and pilot valve.

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

2.2 Sizes and pipe connections - DP17, DP17G, DP17R, DP17Y and DP27G

DN15LC (not available for type DP17G), DN15, DN20, DN25, DN32, DN40 and DN50.

Screwed BSP (BS 21 parallel) or NPT (DN15 to DN25 only).

Standard flanges:

DN15 - DN50 BS 4504 PN16 and PN25

DN25 - DN50 BS 10 Table H and ANSI 300

Available on request:

DN15 - DN50 JIS 10, JIS 16 and ANSI 150

DN15 - DN20 BS 10 Table F

DN15 ANSI 300

IM-P100-05 CTLS Issue 17

100

150

200

100

200

300

400

232

5 10 15 20 25

0 100 200 300

Pressure bar g

Temperature °C

Steam

saturation

curve

Pressure psi g

Temperature °F

2.3 Pressure/temperature limits -

DP17, DP17G, DP17R, DP17Y and DP27G

The product must not be used in this region.

A-D-E Screwed and flanged BS 4504 PN25, ANSI 300, and BS 10 Table H.

A-B-C Flanged ANSI 150.

F-FThe DP17G and DP27G are limited to 120 °C.

Note: DP17, DP17G and DP27G have a variable rate conical pressure adjustable spring

fitted providing a downstream pressure range of 0.2 - 17 bar g.

DP17Y has a pressure spring with a range of 0.2 - 3 bar g.

DP17R Maximum downstream reduced pressure 15 bar g. The control pressure

signal to the pilot diaphragm must be approximately 0.7 bar above the required

reduced downstream pressure.

Body design conditions PN25

PMA Maximum allowable pressure @ 120 °C (248 °F) 25 bar g (362.5 psi g)

TMA Maximum allowable temperature 232 °C (449.5 °F)

Minimum allowable temperature -10 °C (14 °F)

PMO Maximum operating pressure for saturated steam service 17 bar g (246.5 psi g)

TMO Maximum operating

temperature

DP17, DP17Y and DP17R 232 °C (449.5 °F)

DP17G and DP27G 120 °C (248 °F)

Minimum operating temperature 0°C (32 °F)

Note: For lower operating temperatures consult Spirax Sarco.

PMX Maximum differential pressure is limited to the PMO

Designed for a maximum cold hydraulic test pressure of: 38 bar g (551 psi g)

Note: With internals fitted, test pressure must not exceed: 25 bar g (362.5 psi g)

IM-P100-05 CTLS Issue 17

2.4 Sizes and pipe connections - DP17E

DN15LC (not available for type DP17G), DN15, DN20, DN25, DN32, DN40 and DN50.

Screwed BSP (BS 21 parallel) or NPT (DN15 to DN25 only).

Standard flanges:

DN15 - DN50 BS 4504 PN16 and PN25

DN25 - DN50 BS 10 Table H and ANSI 300

Available on request:

DN15 - DN50 JIS 10, JIS 16 and ANSI 150

DN15 - DN20 BS 10 Table F

DN15 ANSI 300

2.5 Pressure/temperature limits - DP17E

Pressure bar g

Temperature °C

Pressure psi g

Temperature °F

100

150

200

232

100

200

300

400

5 10 15 20 25

0 100 200 300

The product must not be used in this region.

The product should not be used in this region or beyond its operating range as

damage to the internals may occur.

Body design conditions PN25

PMA Maximum allowable pressure @ 120 °C (248 °F) 25 bar g (362.5 psi g)

TMA Maximum allowable temperature 232 °C (449.5 °F)

Minimum allowable temperature -10 °C (14 °F)

PMO Maximum operating pressure including saturated steam service 10 bar g (145 psi g)

TMO Maximum operating temperature 190 °C (248 °F)

Minimum operating temperature 0°C (32 °F)

Note: For lower operating temperatures consult Spirax Sarco.

PMX Maximum differential pressure is limited to the PMO

Designed for a maximum cold hydraulic test pressure of: 38 bar g (551 psi g)

Note: With internals fitted, test pressure must not exceed: 25 bar g (362.5 psi g)

IM-P100-05 CTLS Issue 17

Note: Before actioning any maintenance programme 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

DP17, DP17G and DP27G (Fig. 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 (3 - 247 psi).

DP17Y (Fig. 1)

The DP17Y is supplied as the DP17, but has a lower rate pressure adjustment spring for a

downstream pressure range of 0.2 - 3 bar (3 - 44 psi).

Pressure adjustment spring

Internal pressure control

pipe assembly

Pressure setting adjustment screw

Lock-nut

Alternative recommended

downstream pressure control

pipe connection (refer to

Section 3.8, page 14)

Fig. 1 DP17, DP17G and DP17Y

3. Installation

IM-P100-05 CTLS Issue 17

DP17E

The DP17E (Fig. 2) is supplied as for the DP17 with a control spring but the maximum

pressure is limited to 10 bar g (145 psi g) due to the addition of the solenoid valve. A solenoid

operated valve is fitted in the pipe between the pilot valve and the main diaphragm chamber

and is thus in series with the normal pilot valve.

The purpose of the solenoid valve is to override the pilot valve thus causing the main valve

to shut-off. It can be controlled by any device capable of interrupting the supply of current

to the solenoid coil.

The solenoid is arranged to open the valve when the coil is energised so that whatever

switching device is used it must be arranged to break the current to close the main valve.

In this way the unit will always 'fail-safe' i.e. will close the main valve in the event of a failure

in electrical supply.

Electrical supply

It is important that the solenoid is connected to the correct voltage. Therefore always check

on the supply details which are stamped on the solenoid valve name-plate before attempting

to connect up.

Electrical connection is by cable plug to DIN 43650. All wiring, connectors, etc. in close

proximity to the valve should be of heat resisting type and comply with local and national

electrical codes.

Earth

The solenoid valve should be adequately earthed.

Solenoid valve

Fig. 2 DP17E

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