Spirax Sarco DP27 Bedienungsanleitung

IM-P470-03 CH Issue 7

1. Safety information

2. General product

information

3. Installation

4. Commissioning

5. Maintenance

6. Spare parts

7. Fault finding

Printed in GB

IM-P470-03

CH Issue 7

4700036/7

DP27, DP27E, DP27R and DP27Y

Pilot Operated Pressure Reducing Valves

Installation and Maintenance Instructions

IM-P470-03 CH Issue 7

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 European Pressure

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

The products fall within the following Pressure Equipment Directive categories:

Product Group 2

Gases

DP27 and all derivatives

DN15 - DN40 SEP

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. 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 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.

IM-P470-03 CH Issue 7

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-P470-03 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.

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.

IM-P470-03 CH Issue 7

2. General product information

2.1 General description

DP27, DP27E, DP27G, DP27GY, DP27R and DP27Y pilot operated pressure reducing valves

have bodies manufactured using SG iron.These products are not suitable for oxygen service.

Available types

DP27 Suitable for steam or compressed air applications.

DP27E

Suitable for steam applications. It incorporates an electrical

solenoid valve in the pipe assembly allowing remote closure

by means of a switching or timer device.

DP27G

Suitable for compressed air and inert industrial gas

applications. Its design incorporates a nitrile soft seal pilot

and main valve.

Note: it is not available with a solenoid valve.

DP27GY

Suitable for compressed air, inert industrial gas and critical

low pressure control applications. Its design incorporates

a nitrile soft seal pilot and main valve, and uses a lower

rate control spring with a downstream pressure range of

0.2 - 3.0 bar.

Note: it is not available with a solenoid valve.

DP27R

This can be remotely adjusted by varying a pressure signal to

the pilot diaphragm. This is usually achieved using a Spirax-

Monnier pressure regulator and an instrument air supply.

DP27Y

Suitable for steriliser or critical low pressure control

applications. It uses a lower rate control spring with a

downstream pressure range of 0.2 - 3.0 bar.

Standards

This product fully complies with the requirements of the European Pressure Equipment

Directive 97 / 23 / EC and carries the mark when so required.

Certification

This product is available with a manufacturer's Typical Test Report. Note: All

certification / inspection requirements must be stated at the time of order placement.

2.2 Sizes and pipe connections

Screwed BSP (BS 21 parallel) or NPT (DN15, DN20 and DN25 only).

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

Standard flanges:

DN15 - DN50 EN 1092 PN16 and PN25

DN25 - DN50 BS 10 Table H and ASME 300

Flanges available on request:

DN15 - DN50 JIS 10/16 and ASME 150

DN15 - DN20 BS 10 Table F

DN15 ASME 300

IM-P470-03 CH Issue 7

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



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Pressure bar g

Temperature °C

DP27G

and

DP27GY

F F

Pressure bar g

Temperature °C

Steam

saturation

curve G

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2.3 Pressure / temperature limits

Pressure bar g

Temperature °C

Steam

saturation

curve

DP27,

DP27E,

DP27R

and

DP27Y

DP27E

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.

A-D-E Screwed and flanged EN 1092 PN25, ASME 300 and BS 10 Table H

A-B-C Flanged ASME 150.

F-F-E The DP27G and DP27GY are limited to 120 °C.

G-G The DP27E is limited to 10 bar g @ 190 °C.

Note:

DP27 has a variable rate conical pressure adjustable spring fitted providing a downstream

pressure range of 0.2 - 17 bar g.

DP27Y has a pressure spring with a range of 0.2 - 3 bar g.

DP27R 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.

IM-P470-03 CH Issue 7

Body design conditions PN25

Maximum design pressure

A-D-E 25 bar g @ 120 °C

A-B-C 17.2 bar g @ 40 °C

Maximum design temperature 232 °C @ 21 bar g

Minimum design temperature -10 °C

Maximum upstream pressure for saturated steam

service

For ASME 150, see A-B-C

DP27, DP27R and DP27Y 17 bar g

DP27G and DP27GY 25 bar g

DP27E 10 bar g

Maximum operating temperature

For ASME 150, see A-B-C

DP27, DP27Y 232 °C @ 21 bar g

DP27E 190 °C @ 10 bar g

DP27G, DP27GY 120 °C @ 25 bar g

Minimum operating temperature

Note: For lower operating temperatures consult Spirax Sarco 0°C

Maximum differential pressure

DP27, DP27R and DP27Y 17 bar g

DP27G and DP27GY 25 bar g

DP27E 10 bar

Designed for a maximum cold hydraulic test pressure of : 38 bar g

Note: With internals tted, test pressure must not exceed : 25 bar g

IM-P470-03 CH Issue 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

DP27 (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.

DP27Y (Figure 1)

The DP27Y is supplied as the DP27, 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 14)

Fig. 1

DP27 and DP27Y

3. Installation

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