Spirax Sarco DP27 User manual

IM-P470-03 CH Issue 7
1
1. Safety information
2. General product
information
3. Installation
4. Commissioning
5. Maintenance
6. Spare parts
7. Fault finding
© Copyright 2016
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
2

IM-P470-03 CH Issue 7
3
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
4
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
5
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
6
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
7

IM-P470-03 CH Issue 7
8


   




Pressure bar g
Temperature °C
DP27G
and
DP27GY
F F
E
Pressure bar g
Temperature °C
Steam
saturation
curve G
G


   






2.3 Pressure / temperature limits
Pressure bar g
Temperature °C
A
E
Steam
saturation
curve
C
F
F
BD
G
G
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
9
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
10
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