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172-65175MA-13 (COS Pressure Reducing Valve) 16 February 2022

Pressure Reducing Valve for Steam

COS-3/COS-16/COS-21

Copyright © 2022 by TLV CO., LTD.

All rights reserved

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Summary of Contents for COS-16

Page 1: ...172 65175MA 13 COS Pressure Reducing Valve 16 February 2022 Pressure Reducing Valve for Steam COS 3 COS 16 COS 21 Copyright 2022 by TLV CO LTD All rights reserved ...

Page 2: ...specifications and external appearance to make sure nothing is out of the ordinary Also be sure to read this manual carefully before use and follow the instructions to be sure of using the product properly The TLV pressure reducing valve for steam model COS is a new reducing valve that eliminates these problems and makes possible the supply of very dry steam at a constant pressure If detailed inst...

Page 3: ...threat of death or serious injury Indicates that there is a potential threat of death or serious injury Indicates that there is a possibility of injury or equipment product damage NEVER apply direct heat to the float The float may explode due to increased internal pressure causing accidents leading to serious injury or damage to property and equipment Install properly and DO NOT use this product o...

Page 4: ...oduct in any way Failure to observe these precautions may result in damage to the product and burns or other injury due to malfunction or the discharge of fluids Do not use excessive force when connecting threaded pipes to the product Over tightening may cause breakage leading to fluid discharge which may cause burns or other injury Use only under conditions in which no freeze up will occur Freezi...

Page 5: ...s or other injury CAUTION Refer to the product nameplate for detailed specifications Valve No is displayed for products with options This item is omitted from the nameplate when there are no options Acceptable Operating Range Model COS 3 COS 16 COS 21 Primary Pressure Range 0 1 to 0 3 MPaG 15 to 45 psig 0 2 to 1 6 MpaG 30 to 250 psig 1 35 to 2 1 MPaG 190 to 300 psig Adjustable Pressure Range All c...

Page 6: ...tarily To save energy it is recommended to install the on off valve as near to the boiler as possible NOTE To prevent water hammer it is recommended that a slow acting motorized on off valve be used In particular if a fast acting on off solenoid valve is used for frequent temperature control the potential water hammer effect can damage the steam using equipment and the COS 3 Installing a Control V...

Page 7: ...straight piping run of 30 d or more when another pressure reducing valve is installed Two stage pressure reduction Example if nominal size is 25 mm 1 in have 750 mm 30 in or more 2 Outlet secondary side of the COS Maintain a straight piping run of 15 d or more when a manual valve a strainer or an elbow etc is installed Example if nominal size is 25 mm 1 in have 375 mm 15 in or more Maintain a stra...

Page 8: ...lve 16 Feb 2022 7 Maintain a straight piping run of 30 d or more when another pressure reducing valve is installed Two stage pressure reduction Example if nominal size is 25 mm 1 in have 750 mm 30 in or more 30d or more COS Less than 30d COS ...

Page 9: ...ve Seat 19 Diaphragm 20 Diaphragm Support 21 Spring Housing 22 Coil Spring 23 Adjustment Screw 24 Spanner Cap 25 Plug Sensing Line Port 26 Gasket Pilot Body Main Body 27 Trap Valve Seat Gasket 28 Gasket Trap Body Trap Cover 29 Gasket Main Body Trap Body 30 Main Valve Seat Gasket 31 Pilot Screen Holder Gasket 32 Pilot Valve Seat Gasket 33 Diaphragm Gasket 34 Cylinder Gasket 35 Piston Ring 36 Tensio...

Page 10: ...rt 21 Spring Housing 22 Coil Spring 23 Adjustment Screw 24 Spanner Cap 25 Plug Sensing Line Port 26 Gasket Pilot Body Main Body 27 Trap Valve Seat Gasket 28 Gasket Trap Body Trap Cover 29 Gasket Main Body Trap Body 30 Main Valve Seat Gasket 31 Pilot Screen Holder Gasket 32 Pilot Valve Seat Gasket 33 Diaphragm Gasket 34 Cylinder Gasket 35 Piston Ring 36 Tension Ring 37 Main Valve Spring 38 Pilot Va...

Page 11: ...Coil Spring 23 Adjustment Screw 24 Spanner Cap 25 Plug Sensing Line Port 26 Gasket Pilot Body Pilot Cover 27 Trap Valve Seat Gasket 28 Gasket Trap Body Trap Cover 29 Gasket Main Body Trap Body 30 Main Valve Seat Gasket 31 Pilot Screen Holder Gasket 32 Pilot Valve Seat Gasket 33 Diaphragm Gasket 34 Pilot Cover 35 Piston Ring 36 Tension Ring 37 Main Valve Spring 38 Pilot Valve Spring 39 Seal Ring 40...

Page 12: ...nel 1 Blowdown Before installing the COS unit be sure to blow down all piping thoroughly If this is not possible perform a blowdown using the bypass valve Blowdown is especially important for newly installed piping or after the system has been shut down for a long period of time 2 Removing Seal and Cap Before installation be sure to remove all protective seals and caps Found in 3 locations on the ...

Page 13: ... be sure to use a blowdown valve 1 Remove the plug from the main body 2 Install the blowdown valve 3 Open the blowdown valve and blow any residual dirt and scale off of the screen 4 Periodically activate the blowdown valve to keep the system free of dirt and scale 9 Piping Size If it is expected that the secondary steam flow velocity will be more than 30 m s 100 ft s install a diffuser in order to...

Page 14: ...ondensate are recommended for inlet and outlet shut off valves The bypass pipe should be at least 1 2 of the size of the inlet primary side pipe Safety Valve Relief Valve Pressure Gauge Shut off Valve Bypass Valve Inlet Outlet Pressure Gauge Pressure Gauge COS COS Bypass Valve Shut off Valve Shut off Valve Shut off Valve Safety Valve Relief Valve Pressure Gauge Shut off Valve Bypass Valve Inlet Ou...

Page 15: ... and remove the pilot body 2 Install the provided blind pin by first removing the connecting tube from the main body and then substituting the blind pin 3 Re install the pilot body and fasten the hex bolts nuts evenly 4 Remove the plug Rc PT 3 8 or NPT 3 8 and connect the secondary pressure sensing line with a slightly falling pitch The end of the external secondary pressure sensing line should be...

Page 16: ...d 3 Remove the spanner cap loosen the locknut and turn the adjustment screw counterclockwise to reduce tension on the coil spring 4 Slowly fully open the shut off valve at the inlet of the COS Allow sufficient time for condensate remaining at the inlet of the COS to be discharged 5 Slightly open the shut off valve at the outlet of the COS 6 Turn the adjustment screw until the desired outlet pressu...

Page 17: ...spection and Maintenance Frequency Screens Separator and Pilot Disassemble and clean annually If there is substantial blockage install a strainer approximately 60 mesh ahead of the COS Main Valve Main Valve Seat Pilot Valve and Pilot Valve Seat Replace after approximately 15 000 hours If there is chattering or dirt premature wear may result Piston Ring Replace after approximately 8 000 hours If th...

Page 18: ...r after equipment such as a heater is out of service for a long period of time Installation inspection maintenance repairs disassembly adjustment and valve opening closing should be carried out only by trained maintenance personnel Remove all steam from the piping both upstream and downstream If the steam supply to the system cannot be shut off change over to bypass operation Close shut off valves...

Page 19: ...the pilot valve flaws on the gaskets and clogging of the screen Check for deformation corrosion or faults on the diaphragm The diaphragm should be convex open downward with the printed UP mark on the top 15 to 50 mm 1 2 to 2 in 65 to 100 mm 21 2 to 4 in Diaphragm Pilot Valve Seat Gasket Pilot Valve Pilot Valve Spring Plug Pilot Body Gasket Notch Hex Bolt Pilot Screen Pilot Screen Holder Gasket Dia...

Page 20: ...he tension rings from the piston Do not apply too much force when removing the piston rings and tension rings Check for the interior of the cylinder the exterior of the piston rings the small hole on the piston and the gaskets for any fault or abnormality 15 to 50 mm 1 2 to 2 in 65 to 100 mm 21 2 to 4 in Piston Cylinder Connecting Tube Gasket Piston Ring Tension Ring Piston Ring Tension Ring Conne...

Page 21: ...nd remove it from the body Check for damage on the seating and sliding surfaces of the main valve and main valve holder the seating surface of the valve seat the gaskets and for clogging of the screen At start up following shut down for a long period always blow down the piston section of the body through the plug option 15 to 50 mm 1 2 to 2 in 65 to 100 mm 21 2 to 4 in Body Main Valve Seat Gasket...

Page 22: ...1 2 to 2 in 65 to 100 mm 21 2 to 4 in Cleaning After inspection and removal of any abnormality clean and reassemble the parts The following parts will require cleaning before reassembly Trap Cover Piston Float Piston Ring Trap Valve Seat Cylinder Pilot Screen Separator Screen Main Valve Seat Pilot Valve Main Valve Pilot Valve Seat Main Valve Holder Adjustment Screw It is permissible to clean using...

Page 23: ...175MA 13 COS Pressure Reducing Valve 16 Feb 2022 22 Exploded View 15 to 50 mm 1 2 to 2 in 65 100 mm 21 2 to 4 in Adjustment Section Pilot Section Piston Section Separator Main Valve Section Steam Trap Section ...

Page 24: ...nd adjustment screw Apply a small amount of anti seize to the threads of the valve seat pilot valve seat and screen holder Apply anti seize carefully to ensure it does not come into contact with other parts 3 Fasten the bolts one at a time in an alternating diagonal pattern to provide uniform seating 4 After assembly make sure that the piston and the pilot valve operate smoothly without binding 1 ...

Page 25: ... 5 8 21 32 60 44 50 80 2 3 19 3 4 70 51 100 4 24 15 16 150 110 Main Valve Seat 15 20 1 2 3 4 36 17 16 100 73 25 1 41 15 8 125 92 32 40 11 4 11 2 60 23 8 250 185 50 2 70 23 4 300 220 65 100 mm Hex Bolt 65 80 21 2 3 13 1 2 30 22 100 4 16 17 5 8 21 32 40 29 Bolts Float Cover 15 20 1 2 3 4 8 5 16 7 5 25 40 1 11 2 10 3 8 10 7 50 100 2 4 13 1 2 20 15 Trap Valve Seat 15 20 1 2 3 4 11 7 16 10 7 25 40 1 11...

Page 26: ...the above problems are usage under non specified conditions out of specifications insufficient pressure or flow rate and clogs by dirt and scale To ensure performance for a long period of time it is recommended that the Acceptable Operating Range Correct Usage of the COS Reducing Valve and Adjustment sections be reviewed It is a recommended practice to dismantle and inspect the product once a year...

Page 27: ...new valve if necessary There is a build up of dirt on or damage to the pilot valve seat or main valve seat Clean Align Replace if necessary Hunting or chattering occurs Occurs at low steam demand It is being operated below the lower flow rate limit Check the volume of steam supply replace with a smaller diameter valve Hunting never stops There is too high a reduction ratio operated at below 10 of ...

Page 28: ...g No condensate is discharged The primary pressure exceeds the trap valve seat maximum working pressure Adjust primary pressure Water is inside the float Replace with a new float The outlet piping is clogged Check the piping Clean The trap valve seat is clogged Clean Replace with a new trap valve seat NOTE When replacing parts for the COS 3 COS 16 and COS 21 use the parts list for reference and re...

Page 29: ...her cause beyond the control of TLV TII or TLV group companies or 6 improper storage maintenance or repair or 7 operation of the Products not in accordance with instructions issued with the Products or with accepted industry practices or 8 use for a purpose or in a manner for which the Products were not intended or 9 use of the Products in a manner inconsistent with the Specifications or 10 use of...

Page 30: ... COST OF DISASSEMBLY AND SHIPMENT OF THE DEFECTIVE PRODUCT INJURY TO OTHER PROPERTY DAMAGE TO BUYER S OR THE FIRST END USER S PRODUCT DAMAGE TO BUYER S OR THE FIRST END USER S PROCESSES LOSS OF USE OR OTHER COMMERCIAL LOSSES WHERE DUE TO OPERATION OF LAW CONSEQUENTIAL AND INCIDENTAL DAMAGES UNDER THIS WARRANTY UNDER ANY OTHER EXPRESS WARRANTY NOT NEGATED HEREBY OR UNDER ANY IMPLIED WARRANTY NOT NE...

Page 31: ...Road Nunawading Victoria 3131 Australia Tel Fax 61 0 3 9873 5610 61 0 3 9873 5010 In East Asia 36 Kaki Bukit Place 02 01 02 Singapore 416214 Tel Fax 65 6747 4600 65 6742 0345 5 F Building 7 No 103 Caobao Road Xuhui District Shanghai China 200233 Tel Fax 86 0 21 6482 8622 86 0 21 6482 8623 No 16 Jalan MJ14 Taman Industri Meranti Jaya 47120 Puchong Selangor Malaysia Tel Fax 60 3 8065 2928 60 3 8065 ...

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