Spirax Sarco DP143 User manual

IM-P006-07 CTLS Issue 12 1
1. Safety information
2. General product information
3. Installation
4. Commissioning
5. Maintenance
6. Spare parts
7. Fault finding
© Copyright 2018
Printed in GB
0060026/12
DP143, DP143G, DP143H
and DP163, DP163G, DP163Y
Pilot Operated Pressure Reducing Valves
Installation and Maintenance Instructions
IM-P006-07
CTLS Issue 12

IM-P006-07 CTLS Issue 12
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IM-P006-07 CTLS Issue 12 3
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 these 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
DP143 and all derivatives
DN15 - DN32 SEP
DN40 - DN80 1
DP163 and all derivatives
DN15 - DN32 SEP
DN40 - DN80 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 allname-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. Safety information

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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.
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.

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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.
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.
Warning
If this product is not used in the manner specified by this IMI, then the protection provided
may be impaired.

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These instructions relate to the use of the DP143
(Section 2.1) and DP163 (Section 2.2) pilot operated
pressure reducing valves on steam applications but can be
used as a guide when the valve is used on compressed air
applications. The DP143G and DP163G are recommended
for compressed air applications, both having a nitrile seal
for the main valve and pilot valve assemblies.
Note: For additional information see the relevant Technical
Information Sheet.
2.1 DP143, DP143G and DP143H
2.1.1 Description
The DP143, DP143G and DP143H pilot operated pressure
reducing valves have been manufactured using cast steel.
Available types
DP143 Suitable for steam applications
DP143G Is a soft seal version available for
compressed air and inert industrial
gases.
Note: It is not recommended for
oxygen service.
DP143H Is a high temperature version for use up
to 350 °C.
Sizes and pipe connections
DN15LC - Low Capacity version, DN15, DN20, DN25, DN32, DN40, DN50 and DN80.
Standard flanges: EN 1092 PN25 and PN40, BS 10 Table 'J' and ASME 300.
Available on request: ASME 150 and JIS 20.
2. General product information

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0
0
100
200
300
350
10 17.2 20 26 30 40
2.1.2 Pressure/temperature limits
Pressure bar g
Temperature °C
A B
F
Steam
saturation
curve
D
EGC
The product must not be used in this region.
Use the high temperature DP143H version in this region.
A-D-EFlanged EN 1092 PN40, ASME 300 and BS 10 Table J.
A-B-CFlanged ASME 150.
F-GDP143G limited to 120 °C @ 26 bar g.
Note: Two colour coded pressure adjustment springs are available for the following downstream pressure
ranges:
Red 0.2 bar g to 17 bar g
Grey 16.0 bar g to 24 bar g
Body design conditions PN40
Maximum design pressure
A-D-E40 bar g @ 40 °C
A-B-C17.3 bar g @ 40 °C
Maximum design temperature 350 °C @ 24 bar g
Minimum design temperature 0°C
Maximum upstream pressure for saturated steam service
A-D-E28 bar g
A-B-C14 bar g
Maximum operating temperature
DP143 300 °C @ 25 bar g
DP143G 120 °C @ 26 bar g
DP143H 350 °C @ 24 bar g
Minimum operating temperature
Note: For lower operating temperatures consult Spirax Sarco.
0°C
Maximum differential pressure
A-D-E28 bar
A-B-C14 bar
Designed for a maximum cold hydraulic test pressure of: 60 bar g
Note: With internals fitted, test pressure must not exceed: 40 bar g

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2.2 DP163, DP163G and DP163H
2.2.1 Description
The DP163, DP163G and DP163Y pilot operated
pressure reducing valves have been manufactured
using stainless steel.
Available types
DP163 Suitable for steam applications
DP163G Is a soft seal version available for compressed
air and inert industrial gases.
Note: It is not recommended for oxygen
service.
DP163Y Having a lower rate pressure control spring is
suitable for steriliser/autoclave applications
2.2.2 Sizes and pipe connections
DN15LC - Low Capacity version, DN15, DN20, DN25, DN32, DN40, DN50 and DN80.
Standard flanges: EN 1092 PN25 and PN40, BS 10 Table 'J' and ASME 300.
Available on request: ASME 150 and JIS 20.

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0 10 18.9 26 30 36.4 40
0
50
100
150
200
250
Pressure bar g
Temperature °C
2.2.3 Pressure/temperature limits
A B D
G EC
F
Steam
saturation
curve
The product must not be used in this region.
A-D-EFlanged EN 1092 PN40, BS 10 Table J and ASME 300.
A-B-CFlanged ASME 150.
F-GDP163G limited to 120 °C @ 26 bar g.
Note: Two colour coded pressure adjustment springs are available for the following downstream
pressure ranges:
Red 0.2 bar g to 17 bar g
Grey 16.0 bar g to 21 bar g
Yellow 0.2 bar g to 3.0 bar g (DP163Y only)
Body design conditions PN40
Maximum design pressure
A-D-E36.4 bar g @ 20 °C
A-B-C18.9 bar g @ 20 °C
Maximum design temperature 250 °C @ 24 bar g
Minimum design temperature -10 °C
Maximum upstream pressure for saturated steam service
A-D-E25 bar g
A-B-C14 bar g
Maximum operating temperature
A-D-E250 °C @ 24 bar g
A-B-C250 °C @ 12.1 bar g
Minimum operating temperature
Note: For lower operating temperatures consult Spirax Sarco.
0°C
Maximum differential pressure
A-D-E25 bar
A-B-C14 bar
Designed for a maximum cold hydraulic test pressure of: 60 bar g
Note: With internals fitted, test pressure must not exceed: 40 bar g

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Fig. 1
Balance pipe assembly
Pressure adjustment spring
Note: Before actioning any installation observe the 'Safety information' in Section 1.
3.1 Supply (Figure 1)
The DP143 and DP163 pilot operated pressure reducing valves are supplied ready for fitting. The pressure
adjusted spring will be the one most suitable for the downstream pressure quoted on the order but will not
be pre-set.
3. Installation