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Spirax Sarco DP27, Installation And Maintenance Instructions Manual

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Spirax Sarco DP27 Installation And Maintenance Instructions Manual Download Page 1

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

Summary of Contents for DP27

Page 1: ...ct 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 Pressur...

Page 2: ...IM P470 03 CH Issue 7 2...

Page 3: ...tive 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 Che...

Page 4: ...s 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 Pr...

Page 5: ...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...

Page 6: ...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 S...

Page 7: ...IM P470 03 CH Issue 7 7...

Page 8: ...ange 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 limi...

Page 9: ...ar 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 temperat...

Page 10: ...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...

Page 11: ...ys 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...

Page 12: ...o 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 shoul...

Page 13: ...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 sepa...

Page 14: ...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...

Page 15: ...other control valves Fig 7 DP27 position in relation to other control equipment D C B A A Line or system isolation valves A either remotely actuated or manual should be installed on the upstream side...

Page 16: ...anner 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...

Page 17: ...nd 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 Sect...

Page 18: ...enance 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 follo...

Page 19: ...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 n...

Page 20: ...ation 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...

Page 21: ...able 1 Recommended tightening torques for spring housing actuating chamber cover securing studs and nuts Size of valve Nut size Tightening torques DN15 DN20 DN25 and DN32 M10 40 50 N m DN40 and DN50 M...

Page 22: ...strainer screen and clean or replace 17 Ensure the gasket faces are clean 18 Check that the main valve return spring is in position 19 Fit a new gasket 20 Replace the internal strainer screen 21 DP27...

Page 23: ...IM P470 03 CH Issue 7 23 14 15 13 13 16 22 20 19 18 14 21 17 17...

Page 24: ...t all contact faces are cleaned New diaphragms should be fitted such that the precoated sealant which is only applied to one diaphragm faces down contacting the sealing face of the diaphragm chamber 2...

Page 25: ...educing valve and zero the pressure 27 Undo the long union nut and pull away 28 Undo the M12 nuts and bolts 29 Drop away the lower diaphragm chamber the two diaphragms diaphragm plate and the pushrod...

Page 26: ...ould face outwards and slide into position If the diaphragms are not renewed but cleaned only care must be taken to replace the diaphragms in their original order 33 Push the lower diaphragm chamber h...

Page 27: ...or renew the main valve and seat DP27 DP27E and DP27Y Isolate the reducing valve and zero the pressure DP27R Isolate the actuating air supply and zero the pressure 35 Unscrew the unions and release t...

Page 28: ...they are only slightly worn they may be lapped on a flat plate using a fine grinding paste If either is badly worn or unfit for further use they must be replaced 41 Refit the valve seat applying join...

Page 29: ...F Inside 300 330 N m DN40 30 mm A F Inside 450 490 N m DN50 41 mm A F Inside 620 680 N m 45 Refit the pushrod assembly 46 Refit the main valve head make sure valve locates on seat 47 Check the valve...

Page 30: ...a torque of 80 100 N m 52 Retighten the long union nut to ensure a steam tight seal 53 Refit the main valve head 54 Replace the main valve return spring 55 Fit a new gasket 56 Replace the internal st...

Page 31: ...IM P470 03 CH Issue 7 31 51 52 55 54 58 58 56 57 53...

Page 32: ...re now accessible for cleaning replacement Replace worn or damaged parts with a complete Spare parts kit item W pages 34 and 35 for best results 61 Reassemble in reverse order paying careful attention...

Page 33: ...a a a b f f a b c d e Main diaphragm a a a b a a a b b c c Pilot diaphragms a a a a a a a a a a a Pilot valve assembly a a a a a a a a a b b Pilot filter element a a a a a a a a a a a Main valve asse...

Page 34: ...pipe assembly P Downstream pressure balance pipe assembly internal pressure sensing pipe Q Body gasket 3 off R Pilot valve block gasket DP27R only R1 Set of spring housing actuating chamber cover sec...

Page 35: ...IM P470 03 CH Issue 7 35 Y V A R V T T Solenoid valve complete X1 X2 N K L Main valve assembly O M Q S E F P R B C DP27 DP27R and DP27Y S W DP27R DP27E S R1 C1 DP27E or...

Page 36: ...stment spring broken 3 Pipe assembly Item P on page 29 blocked Remove by uncoupling union nuts and blow through to clear obstruction 4 Control orifice blocked Unscrew from outlet port and clear out ob...

Page 37: ...itions it is possible that there is a partial blockage upstream or that the upstream pipework is undersized If the upstream pressure is low the effect will be to reduce the capacity of the valve with...

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