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172-65174MA-11 (COSR Pressure Reducing Valve) 16 Feb 2022

Disassembling the Main Valve and Cover Plug/Cover Section

Turn the COSR

upside down for easy dismantling of the main valve.

Remove the cover plug or loosen the bolts and remove the cover. Remove the main
valve and the main valve spring. Loosen the main valve seat by using a box wrench
and remove from the main body.



Check for damage on the seating and sliding surfaces of the main valve and main valve

holder, the seating surface of the main valve seat, and for damage on the gaskets.

At start-up following shut-down for a long period, always blow down the piston
section of the body through the plug (option).

Main Body

Cover Plug

Cover Plug Gasket

Sleeve (fixed)

Main Valve

Spring

Main Valve Holder

Main Valve

Main Valve Seat

Main Valve Seat Gasket

Main Body

Main Valve Spring

Sleeve (fixed)

Main Valve Holder

Main Valve

Main Valve Seat

Main Valve Seat Gasket

Cover Gasket

Cover

Cover Bolt

Main Body

Main Valve Spring

Sleeve (fixed)

Main Valve Holder

Main Valve

Hex Bolt

Main Valve Seat

Main Valve Seat Gasket

Cover Gasket

Cover

Cover Bolt

COSR-16: 65 to 150 mm (2

to 6 in)

COSR-21: 65 to 100 mm (2

to 4 in)

COSR-3: 20, 25 mm (

, 1 in)

COSR-16: 15 to 25 mm (

to 1 in)

COSR-3/16: 32 to 50 mm (1

to 2 in)

COSR-21: 15 to 50 mm (

to 2 in)

Содержание COSR-16

Страница 2: ...arance 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 COSR provides a more stable secondary pressure than conventional reducing valves The COSR is designed for long service life with all major components made of stainless steel for ...

Страница 3: ...ich poses a 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 Install properly and DO NOT use this product outside the recommended operating pressure temperature and other specification ranges Improper use may result in such hazards as damage to the product or malfuncti...

Страница 4: ... 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 Freezing may damage the product leading to fluid discharge which may cause burns or other injury Use only under conditions in which no water hammer will occur T...

Страница 5: ...ed 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 COSR 3 COSR 16 COSR 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 conditions must be met 0 01 0 05 MPaG 1 5 to 7 psig Within 10 to ...

Страница 6: ...tall 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 COSR 3 Installing a Control Valve A control valve installed between the CO...

Страница 7: ...COSR 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 straight piping run of 30 d or more when a safety valve is installed Example if nominal size is 25 mm 1 in have 750 mm 30 in or more Maintain a straight piping run of 30 d or more when another COSR is installed Tw...

Страница 8: ...172 65174MA 11 COSR Pressure Reducing Valve 16 Feb 2022 7 Configuration COSR 3 COSR 6 15 to 25 mm 1 2 to 1 in ...

Страница 9: ...et 8 Pilot Body 23 Pilot Screen Holder Gasket 9 Pilot Valve 24 Pilot Valve Seat Gasket 10 Pilot Valve Seat 25 Upper Pilot Body Gasket 11 Diaphragm 26 Cylinder Gasket 12 Pilot Screen 27 Piston Ring 13 Pilot Screen Holder 28 Tension Ring 14 Diaphragm Support 29 Main Valve Spring 15 Coil Spring 30 Pilot Valve Spring Replacement parts are available only in the following kits A Maintenance Kit B Repair...

Страница 10: ... Gasket 7 Cylinder 22 Main Valve Seat Gasket 8 Pilot Body 23 Pilot Screen Holder Gasket 9 Pilot Valve 24 Pilot Valve Seat Gasket 10 Pilot Valve Seat 25 Upper Pilot Body Gasket 11 Diaphragm 26 Cylinder Gasket 12 Pilot Screen 27 Piston Ring 13 Pilot Screen Holder 28 Tension Ring 14 Diaphragm Support 29 Main Valve Spring 15 Coil Spring 30 Pilot Valve Spring Replacement parts are available only in the...

Страница 11: ...e Seat Gasket 8 Pilot Body 25 Upper Pilot Body Gasket 9 Pilot Valve 26 Cylinder Gasket 10 Pilot Valve Seat 27 Piston Ring 11 Diaphragm 28 Tension Ring 12 Pilot Screen 29 Seal Ring 13 Pilot Screen Holder 30 Pilot Valve Cover 14 Diaphragm Support 31 Main Valve Spring 15 Coil Spring 32 Pilot Valve Spring 16 Spring Housing 33 Silencer 17 Adjustment Screw Replacement parts are available only in the fol...

Страница 12: ...jury from the discharge of fluids CAUTION Installation inspection maintenance repairs disassembly adjustment and valve opening closing should be carried out only by trained maintenance personnel 1 Blowdown Before installing the COSR 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 pipin...

Страница 13: ...t is necessary to accommodate installation install a spacer on the outlet flange The spacer should consist of a spacer gaskets bolts and nuts Fit gaskets to both sides of the spacer between the COSR outlet and the pipe flange Fasten with bolts and nuts Correct spacer location Incorrect spacer location ...

Страница 14: ...than 30 m s 100 ft s install a diffuser in order to keep the flow velocity below 30 m s 100 ft s If the distance between the reducing valve and the steam using equipment is great a possible drop in pressure should be taken into consideration when selecting the piping size In addition when installing the strainer the strainer screen should be either at the 3 o clock or 9 o clock position to prevent...

Страница 15: ...alves The bypass pipe should be at least one half of the size of the inlet primary side pipe If installing a strainer before the COSR horizontal installation with the basket in the same horizontal plane to the piping is recommended in order to prevent condensate pooling Safety Valve Relief Valve Pressure Gauge Shut off Valve Bypass Valve Inlet Outlet Pressure Gauge Pressure Gauge Pressure Reducing...

Страница 16: ...move 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 connected to the place on the steam using equipment where the pressure is to be sensed A shut off valve should be installed in the external secondary pressure sensing line 15 to 50 mm 1 2 to 2 in 65 to 150 mm 21 2 to 6 in...

Страница 17: ... 3 Remove the spanner cap loosen the locknut and turn the adjustment screw counter clockwise to reduce tension on the coil spring 4 Slowly fully open the shut off valve at the inlet of the COSR Allow sufficient time for condensate remaining at the inlet of the COSR to be discharged 5 Slightly open the shut off valve at the outlet of the COSR 6 Turn the adjustment screw until the desired outlet pre...

Страница 18: ...ollowing inspection and maintenance should be performed regularly Part Inspection and Maintenance Frequency Pilot Screen Disassemble and clean annually If there is substantial blockage install a strainer approximately 60 mesh ahead of the COSR 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 resul...

Страница 19: ...intenance 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 at the inlet and outlet of the COSR completely Relieve residual steam pressure by slightly loosening the...

Страница 20: ...e pilot valve seat flaws on the gaskets and clogging of the pilot 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 65 150 mm 21 2 6 in Diaphragm Pilot Valve Seat Gasket Pilot Valve Pilot Valve Spring Plug Pilot Body Gasket Notch Hex Bolt Pilot Screen Pilot Screen Holder Gasket ...

Страница 21: ...e 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 cylinder gaskets for any fault or abnormality 15 to 50 mm 1 2 to 2 in 65 to 150 mm 21 2 to 6 in Piston Cylinder Connecting Tube Gasket Piston Ring Tension Ring Piston Ring Tension Ri...

Страница 22: ... At start up following shut down for a long period always blow down the piston section of the body through the plug option Main Body Cover Plug Cover Plug Gasket Sleeve fixed Main Valve Spring Main Valve Holder Main Valve Main Valve Seat Main Valve Seat Gasket Main Body Main Valve Spring Sleeve fixed Main Valve Holder Main Valve Main Valve Seat Main Valve Seat Gasket Cover Gasket Cover Cover Bolt ...

Страница 23: ...ts The following parts will require cleaning before reassembly Cover Plug Cover Main Valve Cylinder Pilot Screen Main Valve Holder Pilot Valve Main Valve Seat Piston Pilot Valve Seat Piston Ring Adjustment Screw It is permissible to clean using water however cleaning with a mild detergent is recommended for more effective cleaning Exploded View ...

Страница 24: ...n mm in N m lbf ft Bolts Spring Housing Pilot Body All 16 17 5 8 21 32 40 29 Pilot Valve Seat All 19 3 4 70 51 Pilot Screen Holder All 24 15 16 40 29 Bolts Pilot Body Main Body 15 40 1 2 11 2 16 17 5 8 21 32 60 44 50 2 19 3 4 70 51 Bolts Pilot Body Pilot Cover 65 150 21 2 6 16 17 5 8 21 32 60 44 Bolts Pilot Cover Main Body 65 80 21 2 3 19 3 4 70 51 100 125 4 5 24 15 16 150 110 150 6 36 17 16 300 2...

Страница 25: ...d conditions out of specification 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 COSR Pressure Reducing Valve and Adjustment sections be reviewed Problem Symptom Cause Remedy The secondary pressure does not rise The body is not warm No steam is being supplied o...

Страница 26: ...ow 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 the primary pressure Use a two stage reduction arrangement The selected model is inappropriate for the service conditions specifications Check the model selection replace the COSR if necessary Chattering never stops Condensate is conta...

Страница 27: ...ause 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 the ...

Страница 28: ... 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 NEGATED...

Страница 29: ...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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