Model GP-1000 Series Pressure Reducing Valve Installation & Operation Manual
Model GP-1000 Series Pressure Reducing Valve Installation & Operation Manual
Model GP-1000 Series Pressure Reducing Valve Installation & Operation Manual
Please read this bulletin thoroughly before using the pressure reducing valve, so that you may
do so correctly and safely. Please carefully store this bulletin in a handy place.
Contents
1. Features ····················································································1
2. Specifications ············································································1
3. Dimensions and Weights ···························································2
4. Operation···················································································3
5. Nominal Size Selection Method
5.1 Specifications selection chart ···············································4
5.2 Safety valve setting pressure ···············································4
5.3 Characteristics chart ····························································4
5.4 Nominal size selection chart ················································5
5.5 Nominal size selection calculation formula ··························6
6. Installation
6.1 Example of piping ································································6
6.2 Precautions during installation ·············································7
7. Operating Procedure
7.1 Precautions during operation ···············································8
7.2 Adjustment procedures ························································8
8. Maintenance Procedure
8.1 Troubleshooting ···································································9
8.2 Precautions during maintenance and inspection ··············· 10
8.3 Disassembly······································································· 10
8.4 Precautions during reassembly ·········································· 11
8.5 Exploded drawing ······························································ 12
After Sale Service
■EPDT-081c■
1. Features
GP-1000 Series pressure reducing valves for steam are pilot-operated valves which can be used with
confidence for small to large flow rate, in a host of applications ranging from building utilities systems,
air-conditioning systems, and factory systems, etc.
2. Specifications
Caution
(1) Please collate with attached nameplate and specification of ordered model.
※Please consult factory in case they do not match each other.
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3. Dimensions and Weights
• GP-1000,1000H,1002
(㎜)
Size L H H1 Weight(kg)
15A 150 285 64 8.0
20A 155 285 64 8.5
25A 160 300 67 10.0
32A 190 323 82 14.0
40A 190 323 82 14.5
50A 220 347 93 20.0
65A 245 357 100 30.0
80A 290 404 122 35.0
100A 330 450 144 52.5
• GP-1010,1012
(㎜)
Size d L H H1 Weight(kg)
15A Rc 1/2 150 285 64 7.0
20A Rc 3/4 155 285 64 7.0
25A Rc 1 160 300 67 8.5
32A Rc 1-1/4 190 323 82 12.0
40A Rc 1-1/2 190 323 82 12.5
50A Rc 2 220 347 93 18.0
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4. Operation
The pressure-reducing valve reduces pressure by the throttling the valve. The valve is composed of the
main valve and main valve seat for throttling, and adjusting spring, diaphragm, pilot valve, and piston
for pressure sensing and activation.
(1) When the pressure-reducing valve is mounted correctly, releasing the compression of adjusting
spring [8] allows the spring to close main valve [11] and pilot valve [19]. Slowly open the gate valve
and allow the high-pressure fluid to flow in. Inlet pressure is applied to the downside of the main
valve. High-pressure fluid passes through strainer [28] via inlet pressure passage [42] to also apply
inlet pressure to the downside of the pilot valve.
(2) Turing adjusting screw [9] clockwise compresses the spring, which flexes diaphragm [5] to open the
pilot valve.
(3) Inlet pressure via inlet pressure passage and pilot valve enters the upside of the piston. The pressure
overrides the pressure on the downside of the main valve and the load of main valve spring[13], to
open the main valve. The fluid then begins to flow from the inlet side.
(4) Reduced pressure is led to diaphragm chamber [44] via reduced pressure sensing port [43]. The
diaphragm receives the reduced pressure to be balanced with the adjusting spring load, and control
the pilot valve travel.
(5) The change of pilot valve travel changes the flow rate of fluid to the upside of the piston, and
controls the main valve travel to obtain appropriate reduced pressure.
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5. Nominal Size Selection Method
5.1 Pressure reducing valve specification selection chart
・Range(A) : GP-1000H
・Range(B) : GP-1000H、
GP-1000(1010)
・Range(C) : GP-1000H、
GP-1000(1010)、
GP-1002(1012)
・Range(D) : GP-1002(1012)
Setting
• Shut-off pressure raise : 0.02 MPa or less
pressure Offset • Offset : 0.03 MPa or less
(Setting pressure: 0.03~0.1 MPa)
pressure
0 5 50 100 (%)
Flow rate
Min.adjustable flow rate Rated flow
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5.4 Nominal size selection chart
[Ex.1]
For example, take a pressure reducing valve whose inlet pressure (P1) is 0.6 MPa, reduced pressure (P2)
is 0.4 MPa, flow rate 800 kg/h. First, find the point of intersection (A) of inlet pressure 0.6 MPa and
reduced pressure 0.4 MPa. Vertically proceed from point (A) to come across the flow rate 800 kg/h,
and regard this point as (B). Point (B) is between nominal sizes 40A and 50A. Select the larger nominal
size 50A.
[Ex.2]
For example, take a pressure reducing valve whose inlet pressure (P1) is 0.8 MPa, reduced pressure (P2)
is 0.05 MPa, flow rate 600 kg/h. First, find the point of intersection (C) of inlet pressure 0.8 MPa and
the diagonal line. Move leftward down the diagonal line to intersection point (D) where the diagonals
line intersect with the reduced pressure 0.05 MPa. Vertically proceed from point (D) to come across the
flow rate 600 kg/h, and regard this point as (E). Point (E) is between nominal sizes 32A and 40A.
Select the larger nominal size 40A.
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5.5 Nominal size selection calculation formula
The appropriate nominal size can be calculated by obtaining the Cv value for the operating conditions
in question, as shown below.
• Cv value calculation formula
P1
P2 > W: Max. steam flow rate [kg/h]
2 P1: Inlet pressure [MPa・A]
Wk
Cv = P2: Reduced pressure [MPa・A]
138 ΔP(P1 + P2) ΔP: P1-P2 [MPa]
k: 1+0.0013 × {super-heated steam
P1
P2 < temp.[℃]-saturated steam
2
temp.[℃]}
Wk
Cv =
120P1
[Ex.]
Take a pressure reducing valve whose inlet
1.0
pressure is 0.8 MPa, reduced pressure is 0.05
0 .7
0 .8
1.0
0 .9
C :Correction coefficient
0.9
(イ) MPa. Find the inlet and reduced pressure
1 .1
(ロ)
1.2
0.8
1 .5
1 .6
a
draw a horizontal line in the leftward
0.7 MP
re direction to point (B) which indicates a
ssu
pr e
let
0.6 :In
P1 correction coefficient of 0.85. For a nominal
0.5
size of 25A, the corrected Cv value would be
calculated as follows:
0.4
0.00 0.05 0.10 0.15 0.20 0.25 0.30 0.35 0.40
4(rated Cv value) × 0.85(correction
P2 :Reduced pressure MPa
coefficient) = 3.4
6. Installation
6.1 Example of piping
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6.2 Precautions during installation
Warning
(1) Because of heavy weight, hold the valve with lifting equipment while piping. Refer to
“3. Dimensions and weights” table for the valve weight.
※Failure to do so may result in injury due to dropping the valve.
(2) In case installing safety valve as safety device at outlet side, joint relief pipe at outlet
of safety valve and guide it to safety place where steam can relief out.
※Failure to do so may result in burns.
Caution
(1) Do not disassemble the valve unreasonably.
※Disassembling the valve at your discretion may affect the original performance.
(2) Remove foreign matter and scales from the lines before connecting the valve.
※Failure to do so may prevent the valve from functioning correctly.
(3) Install a strainer (Recommendation: 100-mesh or close) at the valve inlet side.
※Failure to do so may hamper correct pressure control, which affects the original
performance.
(4) Install a safety valve at the valve outlet sides as safety device for equipment.
※Failure to do so prevents problem identification, resulting in equipment damage.
(5) Install a pressure gauge at both the inlet and outlet sides of the valve.
※Failure to do so may hamper correct pressure adjustment.
(6) Install a steam trap to the inlet sides of the valve to prevent drainage problems.
※Failure to do so may result in drainage problem, affecting the original performance.
(7) When installing quick open and close valves, such as a solenoid valve, install it at
inlet side as much as possible, and secure at least 3 m from the valve.
※Failure to do so may result in malfunction or drastically shortened service life.
(8) When pressure reducing in two stages, secure at least 3 m between the valves.
※Failure to do so may result in malfunction, affecting the original performance.
(9) Install the valve in proper direction of the fluid flow.
※Failure to do so may affect the original performance.
(10) Do not apply excessive load, torque or vibration to the valve.
※Doing so may result in malfunction or drastically shortened service life.
(1) Install the valve perpendicularly to horizontal lines.
(2) Provide the by-pass line. (See 6.1 Example of piping)
(3) When the pressure-reducing ratio is large, install a reducer to keep the flow velocity in the pipe
below 30 m/s or less.
(4) Provide space on the top and bottom of the valve so that the valve can be easily disassembled
and inspected. (See Fig.1)
(mm)
Nominal
A B
size
15A
125
20A 315
25A 135
32A
335 155
40A
50A 345 175
65A 355 190
80A 375 225
100A 395 265
Fig.1
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7. Operating Procedure
7.1 Precautions during operation
Warning
(1) Do not touch the valve directly with bare hands.
※Doing so may result in burns.
(2) Before flow the steam in pipe line, make sure steam can flow without any dangerous at
the end of pipe line and pipe line is connected tightly.
※In case steam blow off, it may result in burns.
Caution
(1)Close the stop valves before and after the pressure reducing valve, and remove all
foreign matter and scales via the by-pass line before operation. And, open each stop
valve slowly.
※Failure to do so may prevent the valve from functioning correctly. And, It may cause
hunting, water hammer, etc., resulting in damage to the valve and other equipment
when the stop valve is opened quickly.
(2)Secondary pressure at by-pass line must be lower than set pressure.
※Safety valve blows in case secondary pressure at by-pass line becomes higher than
set pressure.
(3)When adjusting pressure, slowly turn the adjusting screw
※Incorrect adjustment may cause hunting, water hammer, etc., resulting in damage to
the valve and other equipment.
(4)Remove condensate completely from the line, and close the stop valves before and
after the valve when not using it for long periods of times.
※Rust generated in the valves and lines may cause malfunction.
(5)For the model with handle, be sure to operate the handle manually and turn it while
pushing down. At this time, do not turn with too much torque or do not turn excessively.
※Rust generated in the valves and lines may cause malfunction.
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8. Maintenance Procedure
8.1 Troubleshooting
Problem Cause Solution
1. Incorrect pressure is being used. 1. Correct the pressure.
2. Strainer [28] is clogged. 2. Disassemble and clean the strainer.
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8.2 Precautions during maintenance and inspection
Warning
(1)Completely discharge internal pressure from the valves, lines, and equipment, and cool
the valve down to a level where you can touch it with bare hands before disassembly
and inspection.
※Failure to do so may result in injury or burns due to residual pressure or spillage
around the valve.
Caution
(1)In order to maintain original performance and function, examine daily and personal
inspection. And, periodical inspection must be examined according to the regulations of
every kind.
※For general users, request to specialized dealer or manufacture.
(2)Pressure reducing valve shall be disassembled and inspected by qualified person or
manufacture.
※Request the treatment to specialized dealer or manufacture in case of any problems.
(3)While disassembly, drain flow out from the valve, so catch it by container. And release
steam completely before disassembling.
※In case of no container for drain, it makes dirty surrounding the valve.
(4)Close the stop valves before and after the pressure reducing valve, and remove all
foreign matter and scales via the by-pass line before operation.
※Failure to do so may prevent the valve from functioning correctly.
(5)When adjusting pressure, slowly turn the adjusting screw.
※Incorrect adjustment may cause hunting, water hammer, etc., resulting in damage to
the valve and other equipment.
(6)Remove condensate completely from the line, and close the stop valves before and
after the valve when not using it for long periods of times.
※Rust generated in the valves and lines may cause malfunction.
(7)In case of no operation for a long period of time, perform operating exam before start
operation again.
※Request the treatment to specialized dealer or manufacture in case of any problems.
8.3 Disassembly
Be sure that the stop valves at inlet and outlet side of pressure reducing valve is closed and all internal
pressure and condensate have discharged before disassembling the valve.
(2) Piston
1. Remove the bolt [34] of the top cover [2] and the top cover. Pick up the spindle [18], and
remove the piston ring [16] and the inner ring [17].
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8.4 Precautions during disassembly
Caution
(1) Check that there is no damage and scratches on the main valve, main valve seat, pilot
valve, and pilot valve seat.
※Any scratches at sealing surface lead to increase in secondary pressure. When any
scratches are identified at main valve and seat, polish them away. And, change the
parts if scratches still exist after polishing. Also, in case any scratches are identified
at pilot valve and pilot valve seat, change into pilot valve assembly.
(2) Move the sliding section (pilot valve, piston, etc.) two to three times and confirm they
move smoothly.
※If the sliding parts do not move correctly, it may cause failure problems. (Working not
correctly).
(3) Replace gaskets with new ones when reassembling.
※If the gasket is used for a long time, it may cause steam leakage problem.
(4) Assemble in the reverse order of Disassembly. And tighten the bolts evenly.
※Assemble the valve due to the order. Failure to do so may lead to not assemble
correctly. And if the hexagon bolts are not screwed correctly, it may cause steam
leakage problem.
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8.5 Exploded drawing
Diaphragm [5] and piston ring [16] are used two pieces
for GP-1002 and GP-1012.
Parts with in the flame are consumable. Please contact us for purchase of these consumable parts.
Note (*): Apply a liquid sealant for heat and steam resistant (Recommendation: SOLVEST
110) to the sealing surface of the diaphragm bottom and the top cover.
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Warranty Information
1. Limited warranty
This product has been manufactured using highly-advanced techniques and subjected to
strict quality control. Please be sure to use the product in accordance with instructions on
the manual and the label attached to it.
Yoshitake warrants the product to be free from any defects in material and workmanship
under normal usage for a period of one year from the date of receipt by the original user, but
no longer than 24 months from the date of shipment from Yoshitake’s factory.
3. This warranty does not cover the damage due to any of below:
(1) Valve seat leakage or malfunction caused by foreign substances inside piping.
(2) Improper handling or misuse.
(3) Improper supply conditions such as abnormal water pressure/quality.
(4) Water scale or freezing.
(5) Trouble with power/air supply.
(6) Any alteration made by other than Yoshitake.
(7) Use under severe conditions deviating from the design specifications.
(8) Fire, flood, earthquake, thunder and other natural disasters.
(9) Consumable parts such as O-ring, gasket, diaphragm and etc.
Yoshitake is not liable for any damage or loss caused by malfunction or defect of the product.
INTERNATIONAL DEPT.
7-3, Futanocho, Mizuho, Nagoya, Aichi, 467-0861, Japan
Phone: +81-52-881-7199 Fax: +81-52-881-7201
E-mail: Intntl@yoshitake.co.jp
2009.9
PDD-046c