Yoshitake GP-27 Bedienungsanleitung

EPDT-393a

MODEL GP-27

PRESSURE REDUCING VALVE

PRODUCT MANUAL .

Thank you very much for choosing the Yoshitake’s product. To ensure the correct and safe use of the product,

please read this manual before use. This manual shall be kept with care for future references.

The symbols used in this manual have the following meanings.

Warning

This symbol indicates a potentially hazardous situation that, if not avoided,

could result in death or serious injury.

Caution

This symbol indicates a hazardous situation that, if not avoided, may result in

minor or moderate injury or may result in only property damage.

Table of Contents

1. Specifications····························································1

2. Dimensions and Weights·············································2

3. Operation·································································3

4. Nominal Size Selection method·····································4

4.1 Pressure reducing valve specification selection chart ···4

4.2 Characteristic chart··············································4-5

4.3 Nominal size selection chart ··································6

4.4 Nominal size selection calculation formula ················7

5. Installation

5.1 Piping example····················································7

5.2 Precaution for installation······································7-8

6. Operation procedure

6.1 Precaution for operation ········································9

6.2 Adjusting procedure··············································9

7. Troubleshooting

7.1 Troubleshooting·················································10

7.2 Precaution for maintenance and inspection··············11

7.3 Disassembly·····················································11

7.4 Precaution for reassembly····································12

7.5 Exploded view···················································13

Warranty Information

EPDT-393a

1. Specifications

Model

GP-27

Connection

JIS 10K FF Flanged

Application

Steam

Inlet pressure

0.1-1.0 MPa

Reduced pressure

0.03-0.8 MPa

80% or less of Inlet pressure (gauge pressure)

Min. differential pressure

0.07 MPa

Max. pressure reducing ratio

10:1

Max. temperature

220 ℃

Valve seat leakage

0.05% or less of rated flow

Material

Body

Ductile Cast Iron

Valve, Valve seat

Stainless Steel

Pilot valve, pilot valve seat

Stainless Steel

Piston, Cylinder

Bronze

Diaphragm

Stainless Steel

Caution

Please confirm that the indications on the product correspond with the

specifications of the ordered product model before use.

* If they are different, please contact us without using the product.

2 EPDT-393a

2. Dimensions and Weights

(mm)

Nominal Size

Weight（kg）

125A

375

627

162

150A

420

686

190

135

200A

490

765

220

204

3 EPDT-393a

3. Operation

The pressure-reducing valve reduces pressure by the throttling the valve. The valve is composed

of the main valve and main valve seat for throttling, and adjusting spring, diaphragm, pilot valve,

and piston for pressure sensing and activation.

(1) When the pressure-reducing valve is mounted correctly, releasing the compression of

adjusting spring [21] allows the spring to close main valve [6] and pilot valve [35]. Slowly open

the gate valve and allow the high-pressure fluid to flow in. Inlet pressure is applied to the

downside of the main valve. High-pressure fluid passes through strainer [12] via inlet pressure

passage [39] to also apply inlet pressure to the downside of the pilot valve.

(2) Turning adjusting screw [17] in the direction of the casted arrow with “H” on spring chamber

[4] compresses spring [21] and flexes diaphragm [13], and thus opens pilot valve [35].

(3) Inlet pressure via inlet pressure passage and pilot valve enters the upside of the piston. The

pressure overrides the pressure on the downside of the main valve and the load of main valve

spring [7], to open the main valve. The fluid then begins to flow from the inlet side.

(4) Reduced pressure is led to diaphragm chamber [41] via reduced pressure sensing port [40].

The diaphragm receives the reduced pressure to be balanced with the adjusting spring load,

and control the pilot valve travel.

(5) The change of pilot valve travel changes the flow rate of fluid to the upside of the piston, and

controls the main valve travel to obtain appropriate reduced pressure.

No.

Parts name

Body

Spring Chamber

Cap

Main valve

Main valve seat

Piston

Cylinder

Pilot valve seat

Strainer

Diaphragm

Adjusting screw

Lock nut

Main valve spring

Adjusting spring

Pilot valve

Inlet press. passage

Reduced press. sensing port

Diaphragm chamber

4 EPDT-393a

4. Nominal size selection method

4.1 Pressure reducing valve specification selection chart

Based on the selection chart, select a pressure reducing valve in the optimum manner. On the

selection chart, first find the intersection point of the inlet pressure and the reduced pressure.

Two-stage pressure reduction is required if the intersection point lies in range (A), or the pressures

are controllable with a single pressure reducing valve if the intersection point is within range (B).

The valve does not fulfill specified performance in range (C). To adopt two-stage pressure

reduction, separate two pressure reducing valves as far away from each other as possible (at

least 3m).

4.2 Characteristic chart

(1) Flow rate characteristics chart

* Shut-off pressure rise: 0.02 MPa or less

* Offset: 0.05 MPa or less

5 EPDT-393a

(2) Pressure characteristics chart

This chart shows variation in reduced pressure when the inlet pressure of 0.3 MPa is changed

between 0.3 MPa and 1.0 MPa while the reduced pressure is set at 0.2 MPa.

6 EPDT-393a

4.3 Nominal size selection chart

[Example]

When selecting the nominal size of a pressure reducing valve with its inlet pressure (P1) is 0.6

MPa, its reduced pressure (P2) 0.4 MPa and its steam flow rate 8000 kg/h, first find the intersection

point (A) of inlet pressure 0.6 MPa and reduced pressure 0.4 MPa. Trace down vertically from this

intersection point (A) to find intersection point (B) with the flow rate of 8000 kg/h. Since the

intersection point (B) is between nominal sizes 125A and 150A, select the larger one, 150A.

7 EPDT-393a

4.4 Nominal size selection calculation formula

An appropriate nominal size can be calculated by obtaining Cv value for the operating conditions

in question, as shown below.

•Calculation formula for Cv value

•Rated Cv value table

Nominal size

125A

150A

200A

Cv value

100

144

230

5. Installation

5.1 Piping example

5.2 Precaution for installation

Warning

1. Because of heavy weight, hold the valve with lifting equipment while piping. Refer to “3. Dimensions

and weights”table for the valve weight.

* Failure to follow this notice may result in injury due to dropping the valve.

2. In case installing safety valve as safety device at outlet side, joint relief pipe at outlet of safety valve

and guide it to safety place where steam can relief out.

* Failure to follow this notice may result in injury and scalds in case of fluid blow out.

W: Max. steam flow rate [kg/h]

P1: Inlet pressure [MPa･A]

P2: Reduced pressure [MPa･A]

ΔP: P1－P2 [MPa]

k: 1+0.0013 × {super-heated steam

temp. [ ℃] - saturated

steam temp. [℃]}

2

)PP(P138

Cv 21 +

2

1120P

Cv =

8 EPDT-393a

Caution

1. Do not disassemble the valve unreasonably.

* Disassembling the valve at your discretion may affect the original performance.

2. Remove foreign matter and scales from the lines before connecting the valve.

* Failure to follow this notice may prevent the valve from functioning correctly.

* Repairs caused by foreign substances or scales will be charged even during the warranty

period.

3. Install a strainer (80 mesh) at the valve inlet side.

* Failure to follow this notice may hamper correct pressure control, which affects the original

performance.

4. Install a safety valve at the valve outlet sides as safety device for equipment.

* Failure to follow this notice may prevents problem identification, resulting in equipment damage.

5. Install a pressure gauge at both the inlet and outlet sides of the valve.

* Failure to follow this notice may hamper correct pressure adjustment.

6. Install a steam trap to the inlet sides of the valve to prevent drainage problems.

* Failure to follow this notice may result in drainage problem, affecting the original performance.

7. When installing quick open and close valves, such as a solenoid valve, install it at inlet side as

much as possible, and secure at least 3 m from the valve.

* Failure to follow this notice may result in malfunction or drastically shortened service life.

8. When pressure reducing in two stages, secure at least 3 m between the valves.

* Failure to follow this notice may result in malfunction, affecting the original performance.

9. When installing a control valve, etc. at the outlet side of the valve, secure at least 1m from the

valve.

10.Install the valve in proper direction of the fluid flow.

* Failure to follow this notice may affect the original performance.

11.Do not apply excessive load, torque or vibration to the valve.

* Doing so may result in malfunction or drastically shortened service life.

12. Install the valve perpendicularly to horizontal lines.

13. Provide the by-pass line. (See 5.1 Example of piping)

14. When the pressure-reducing ratio is large, install a reducer to keep the flow velocity in the pipe

below 30 m/s or less.

15. Provide space on the top and bottom of the valve so that the valve can be easily disassembled

and inspected. (See Fig.1)

(mm)

Nominal

size

125A

690

370

150A

725

435

200A

780

495

Fig. 1

9 EPDT-393a

6. Operation procedure

6.1 Precaution for operation

Warning

1. Do not touch the product with bare hands directly.

* Failure to follow this notice may result in scalds.

2. Before applying steam to the product, confirm that there is no risk when steam flows into the piping

end and that piping joints are securely connected.

* Failure to follow this notice may result in scalds in case of steam blow out.

Caution

1. Close the stop valves before and after the pressure reducing valve, and remove all foreign matter

and scales via the by-pass line before operation. And, open each stop valve slowly.

* Failure to follow this notice may prevent the product from functioning properly due to the ingress

of foreign substances and scale into the product.

2. Secondary pressure at by-pass line must be lower than set pressure.

* Safety valve blows in case secondary pressure at by-pass line becomes higher than set pressure.

3. When adjusting pressure, slowly turn the adjusting screw.

* Incorrect adjustment may cause hunting, water hammer, etc., resulting in damage to the valve

and other equipment.

4. To adjust the set pressure, turn the adjusting screw slowly.

* Failure to follow this notice may result in outside leakage or damage of the product due to hunting

or water hammer, etc.

5. Before stopping operation of the product for an extended period, completely discharge fluid from

the product and close the stop valves at the inlet and outlet sides of the product.

* Failure to follow this notice may cause malfunction due to rusting inside the product and the pipes.

6.2 Adjusting procedure

(Please refer to the drawing in “4. Operation” or “8.5 Exploded drawing” for each part name.)

Taking a wrong adjusting procedure may cause hunting, scale problems or water hammer, and can

heavily damage the main parts of the valve. Be sure to follow the procedure below

1.Close the stop valve at inlet and outlet side of the pressure reducing valve, and taking enough time

not to blow the safety valve, blow off the fluid to remove foreign matter via the by-pass line. After

blowing, close the by-pass line stop valve.

2.Remove the cap [5], loosen the locknut [18] and the adjusting screw [17], and release the spring [21]

(no compression).

3.Slowly open the stop valve at the inlet side of the pressure reducing valve, and adjust the travel of the

stop valve at the outlet side of the pressure reducing valve so that a little fluid flow.

4.To adjust the reduced pressure, slowly turn the adjusting screw [17] in the direction of the casted arrow

with “H” on spring chamber [4] while observing the pressure gauge on the outlet side. The pressure

increases when turning the adjusting screw [17] along the arrow, and decreases when turning it to the

opposite direction.

5.Slowly open the stop valve at the outlet of the pressure reducing valve, and readjust the desired

pressure.

6.After adjustment, tighten the lock nut [18] and attach the cap [5].

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