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

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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.

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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.

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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.

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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

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

   




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.

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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

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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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DP27E
The DP27E (Figure 2) is supplied as for the DP27 with
a control spring but the maximum pressure is limited
to 10 bar 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.
Note: A special pilot valve assembly is used in the 'E'
version to prevent leakage past the pilot valve plunger
when the solenoid is used to close the valve.
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.
DP27R
The DP27R (Figure 3) is supplied ready for fitting.
Downstream pressure can be adjusted remotely by a
controlled air supply to the pilot diaphragm chamber. The
actuating air supply must be at a pressure approximately
0.7 bar g above the required downstream pressure and
controlled through a metal bodied self-relieving regulator.
A check valve should be fitted to prevent steam entering
the air system, in the unlikely event of a failure of the pilot
diaphragm. Any filter should be fitted with a metal bowl
and should preferably be on the upstream side of the
check valve.
The actuating air supply controlled by the regulator
should be connected to the union fitting attached to
the air control block as shown in Figure 4. The air inlet
connection is suitable for 6 mm O/D copper tube. The
maximum reduced pressure available through the DP27R
is 15 bar g. Typical installation is shown in Figure 9,
page 17.
Solenoid
valve
Fig. 2 DP27E
Fig. 3 DP27R

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Pressure sensing pipe
Small bore
drain
Strainer with 100 mesh stainless steel screen
Separator
Steam
supply Spiratec
sensor
chamber
Float type
steam trap
Pressure
reducing
valve
DP27 and DP27E
0.9 m or 15 pipe diameters
clear on either side
See Section 3.6, page 13.
Downstream isolating valve to
provide no-load conditions for
setting pressure reducing valve
Safety
valve
Discharge
pipe
Check
valve
Strainer
3.2 Fitting (Figures. 4, 5 and 6)
The valve should always be fitted in a horizontal pipeline with the main diaphragm
chamber below the line (Figure 4). To meet high capacities or widely varying loads, or
where stand-by facility is required, two or more valves may be used in parallel (Figure 5).
For pressure turndown in excess of 10 to 1 consideration should be given to using the two
valves in series. To avoid instability pipework volume between the valves should be equivalent
to at least 50 pipe diameters in length of the intermediate correctly sized pipework. To ensure
adequate drainage of the space between the two reducing valves a trap set should be fitted
as shown in Figure 6.
Separator
Compressed
air
Fig. 4 Recommended installation
Installation for
compressed air Compressed
air trap
DP27R
Compressed air
Regulator
Filter
Float type
steam trap
Alternative for draining separator
Strainer Sight
glass
Check valve
Steam supply

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Fig. 5 Two pressure reducing valves in parallel
Steam supply
Q See Section 3.6
3.3 Pipeline sizing
The piping on both sides of the valve must be sized so that velocities do not exceed 30 m / s.
This means that a properly sized valve will often be smaller than the connecting
pipework.
3.4 Pipeline stresses
Line stresses caused by expansion or inadequate support should not be imposed on the valve
body.
3.5 Isolating valves
These should preferably be of the full bore type.
3.6 Removal of condensate
It is recommended that a separator with trap set is fitted upstream of the valve to ensure dry
steam conditions.
If there is a rise in the low pressure line from the valve then a further drain point should be
provided to keep the valve drained after shutdown.
Steam supply
Q See Section 3.6
Fig. 6 Two pressure reducing valves installed in series
Q
Q
Q
Separator
Trap set Trap set

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3.7 Protection from dirt
The valve should be protected by a pipeline strainer with 100 mesh screen. The strainer
should be fitted on its side to prevent the accumulation of water. The strainer screen should
be examined and cleaned at regular intervals.
3.8 Pressure sensing
For applications that require closer control, improved stability or maximum capacity condition
the internal balance pipe should be replaced by an external pressure sensing pipe (supplied
by others) as follows:
Remove the internal balance pipe assembly.
The resulting BSP tapping in the side of the body should be blanked using the plug provided
in the linen bag attached to the valve (which also contains the fitting instructions). The other
BSP tapping in the side of the pilot valve chamber, should be used to fit the external
pressure sensing pipe. This is suitable for the fitting of 6 mm O/D pipe. If suitable pipe is not
available the compression fitting can be removed and ¼" nominal bore steel pipe screwed
directly into the pilot valve chamber.
The pressure sensing pipe should be connected into the top of the reduced pressure main
at a point where in either direction there is a length of straight pipe uninterrupted by fittings
for at least 1 m or 15 pipe diameters whichever is the greater. It should be arranged with a
positive fall so that any condensate can drain away from the DP27. Where the size of the
reduced pressure main makes it difficult to maintain a fall when entering the top of the main,
the pressure sensing pipe may be connected in the side of the main.
3.9 Pressure gauges
It is essential to fit a pressure gauge on the upstream and downstream side so that the valve
can be properly set and monitored.
3.10 Continuous duty
For continuous duty applications where a constant steam supply is essential then a parallel
stand-by PRV station is recommended to allow for planned maintenance, see Figure 5,
page 13. Alternatively a bypass line can be used (see Figures 8 and 9, page 17). It is
important that the bypass should have a similar capacity to the pressure reducing valve
which is achieved by choosing an appropriately sized valve or by using a reduced orifice
in the line.
The handwheel should be padlocked to prevent unauthorised use, and when in use should
be under constant manual supervision.
The bypass may be arranged above or to the side of the main assembly but never below it.

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3.11 Safety valve
A safety valve should be fitted to protect the downstream equipment from excessive pressure.
It should be set to lift below the safe working pressure of the downstream equipment, and
will normally be sized to pass the full capacity of the PRV should the PRV fail in the fully open
position. The safety valve set pressure should take account of its reseat characteristic and
the 'No-load' pressure setting of the PRV. For example, the typical blowdown value (reseat
differential) for a DIN type safety valve is 10% of set pressure. The minimum possible safety
valve set pressure must therefore equal the no-load set pressure of the reducing valve plus
the blowdown value of the safety valve plus a small margin of at least 0.1 bar. If the safety
valve lifts and the working pressure is too close then it will not be able to close properly and
will simmer, creating a leak which is often wrongly diagnosed as a result of a leaking reducing
valve.
Discharge pipework should be taken to a safe place.
3.12 Position in relation to other control valves
Fig. 7 DP27 position in relation to other control equipment
D
C
B
AA
Line or system isolation valves (A), either remotely actuated or manual, should be installed
on the upstream side of the DP27 reducing valve.
Where there is downstream control equipment (B), particularly when it is fast acting (for
instance pulsed piston actuated valves) ensure the control equipment is at least 50 pipe
diameters away from the DP27 to prevent pressure pulses being transmitted back causing
unstable operation and premature wear or if this is impractical an intermediate vessel can
provide a similar benefit.
Where a safety valve (C) is required to protect the system downstream of a DP27 and where
a control valve is also being used downstream of the DP27, it is recommended that the safety
valve is fitted downstream of the control valve rather than in between the DP27 and the control
valve. If any slight leakage occurs this will avoid any pressure build-up causing nuisance
operation of the safety valve but provide complete protection for the downstream system.
Where valves are installed downstream of the DP27 (B) the intermediate downstream pipework
must be properly trapped (D) to ensure no condensate can build up on the downstream side
of the DP27.
DP27

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4. Commissioning
DP27, DP27E and DP27Y (Figure 8)
2. Close all valves at reducing valve station,
including valves on bypass line if fitted.
3. Check that adjustment screw is turned
fully anticlockwise until spring is slack.
DP27R (Figure 9)
2. Close all valves at reducing valve station,
including the valve on the bypass line, if
fitted.
3. Check that the actuating air supply is off
and the pressure is zero.
4. Check that the pressure gauge isolating cocks are open.
5. For correct operation of the valve it is important that the pilot and main valves are not
subjected to dirt or other hard particles. Therefore, prior to bringing the valve into operation,
ensure that the upstream pipework has been cleared of all loose dirt and hard particles
and that the main strainer screen is examined and cleaned if necessary.
6. Slowly open the upstream isolating valve until it is fully open.
DP27, DP27E and DP27Y
7. Using a 19 mm A/F spanner slowly turn
adjustment screw in a clockwise direction
until desired downstream pressure
reading is obtained.
8. Holding the adjustment screw in position
with the spanner tighten down the lock-nut
to secure the setting of the adjustment
spring.
DP27R
7. Slowly admit actuating air through the
pressure regulator until the desired
downstream pressure is obtained.
Note
To facilitate resetting of the reducing valve it
may be desirable to position the downstream
pressure gauge at a viewpoint close to the air
regulator.
If this necessitates fitting the pressure gauge
below the steam line, the interconnecting pipe
should be drained at the low point otherwise
the gauge will give a false reading.
9. Slowly open the downstream valve until it is fully open.
Note: After installation or maintenance ensure that thet system is fully functional. Carry out
tests on any alarms or protective devices. It is recommended that after commissioning the
pilot filter is changed and the spare one supplied with the valve is fitted.
4.1 Setting procedure (Figure 8 and Figure 9)
1. Ensure that all connections are properly made and that all valves are closed.

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Fig. 8 Setting procedure sequence DP27, DP27E and DP27Y
Fig. 9 Setting procedure sequence DP27R
4.2 Two or more valves in parallel
When more than one reducing valve is used it is an advantage to use two valves of unequal
size, the smaller one being chosen to meet the lower load requirements and the larger valve
to come into operation so that both meet the normal and maximum demand.
It is necessary to commission each valve independently (one at a time) following the procedure
detailed in Section 4.1 but setting the smaller valve at a pressure higher than the larger valve.
Q See Section 3.6, page 11
2
5
2, 9
2, 6
5
3, 7, 8
44
Condensate
return
Steam flow
Optional bypass line (see Section 3.10)
Q
2
5
2, 9
3
2, 6
5
44
Condensate
return
Steam flow
Optional bypass line (see Section 3.10)
Q See Section 3.6, page 11
Q

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5. Maintenance
Note: Before actioning any maintenance programme observe the 'Safety
information' in Section 1.
Warning:
The body gasket (all DP27 derivatives) and actuating chamber gasket (DP27R)
contains a thin stainless steel support ring which may cause physical injury if not
handled and disposed of correctly.
5.1 Routine maintenance
It is recommended that the valve is dismantled once every twelve to eighteen months for a
complete overhaul and ideally this should be carried out with the valve removed from the line.
The following parts should be
inspected and refurbished or
replaced as necessary:
- Main valve seat and valve head.
-Pilot valve assembly.
-Pilot filter element.
-Internal strainer screen.
-Main diaphragms.
-Pilot diaphragms.
Pilot
diaphragms
Main
diaphragms
Main valve seat
and valve head
Internal strainer
screen
Pilot filter element
Body gasket
Pilot valve assembly

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5.2 How to renew the pilot filter element
1. Isolate the reducing valve and zero the pressure.
2. Unscrew the filter cap and carefully withdraw the filter element.
3. Replace the element and tighten the filter cap to 90 - 100 N m.
Note: The gasket is re-usable.
Filter element
Filter cap
5.3 How to renew or change the pressure adjustment spring
Isolate the reducing valve and zero the pressure in order to change the pressure adjustment
spring.
1. Release the adjustment lock-nut.
2. Turn the adjustment screw anticlockwise.
Ensure there is no compression on the
pressure adjustment spring.
3. Undo the 4 off spring housing securing
nuts and remove the spring housing.
4. Remove the pressure adjustment spring
and the top spring plate.
5. Reassemble in reverse order.
1
2
3, 6
4

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5.4 How to renew the pilot valve assembly
6. DP27, DP27E and DP27Y
Isolate the reducing valve and zero the pressure and proceed to unscrew the 4 off spring
housing securing nuts and remove spring housing, bottom spring plate and diaphragms.
DP27R
Isolate the actuating air supply and zero the pressure and proceed to unscrew the 4 off
actuating chamber nuts and remove the air control block and diaphragms.
7. Unscrew and remove the pilot valve assembly (19 mm A/F). The pilot assembly has an
integral PTFE seal.
The following handling precautions should be observed.
Handling precautions for PTFE
Within its working temperature range PTFE is a completely inert material, but when heated
to its sintering temperature it gives rise to gaseous decomposition products or fumes which
can produce unpleasant effects if inhaled. Fumes can be produced during processing: for
example, when the material is heated to sinter it, or when brazed connections are being
made to cable insulated PTFE. The inhalation of these fumes is easily prevented by
applying local exhaust ventilation to atmosphere as near to their source as possible.
Smoking should be prohibited in workshops where PTFE is handled because tobacco
contaminated with PTFE will during burning give rise to polymer fumes. It is therefore
important to avoid contamination of clothing, especially the pockets, with PTFE and to
maintain a reasonable standard or personal cleanliness by washing hands and removing
any PTFE particles lodged under the fingernails.
8. Apply superlube grease to the threads before screwing the new pilot valve into the housing.
Torque 45 - 50 N m.
9. Check that there is a very slight
clearance between the top of the plunger
and a straight edge placed across the
diaphragm location recess.
10. Refit the two diaphragms making sure
that they are fitted the same way round
as they were removed and that all
contact faces are clean. Diaphragms
showing signs of wear or damage should
be replaced.
11. DP27, DP27E and DP27Y
Replace the bottom spring plate.
12. DP27, DP27E and DP27Y
Assemble the spring housing and tighten the nuts to the recommended torques shown
in Table 1.
DP27R
Assemble the air control block and tighten the nuts to the recommended torques shown
in Table 1.
Bring the valve back into commission, following as many Steps as necessary in Section 4,
page 14.
9
Straight edge