1000026/16 IM-P100-05

CTLS Issue 17

DP17, DP17E, DP17G, DP17R, DP17Y and DP27G

Pilot Operated Pressure Reducing Valves
Installation and Maintenance Instructions

1. Safety information

2. General product
information

3. Installation

4. Commissioning

5. Maintenance

6. Spare parts

7. Fault finding

© Copyright 2018
IM-P100-05 CTLS Issue 17 1
Printed in GB
2 IM-P100-05 CTLS Issue 17
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 Pressure Equipment
Directive (PED)and carry the mark when so required. The products fall within
the following Pressure Equipment Directive categories:

Group 2
Product
Gases

DP17, DP17E, DP17G DN15 - DN40 SEP

DP17R, DP17Y and DP27G 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.

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.

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

IM-P100-05 CTLS Issue 17 3

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.

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,

4 IM-P100-05 CTLS Issue 17

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 (572 °F).
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.

1.16 Returning products

Customers and stockists are reminded that under EC Health, Safety and Environment
Law, when returning products to Spirax Sarco they must provide information on
any hazards and the precautions to be taken due to contamination residues or
mechanical damage which may present a health, safety or environmental risk. This
information must be provided in writing including Health and Safety data sheets
relating to any substances identified as hazardous or potentially hazardous.

IM-P100-05 CTLS Issue 17 5

2. General product information
2.1 General description
These instructions apply to the DP17 and most derivatives including the DP17E, DP17G,
DP17R, DP17Y and DP27G.
The instructions primarily relate to the use of the DP17 on steam but can be used as a guide
when the valve is used on compressed air.
For compressed air the DP17G and DP27G are recommended which have a nitrile seal for
both the main valve and pilot valve.
Note: For additional information see the relevant Technical Information Sheets.

2.2 Sizes and pipe connections - DP17, DP17G, DP17R, DP17Y and DP27G
DN15LC (not available for type DP17G), DN15, DN20, DN25, DN32, DN40 and DN50.
Screwed BSP (BS 21 parallel) or NPT (DN15 to DN25 only).

DN15 - DN50 BS 4504 PN16 and PN25

Standard flanges:
DN25 - DN50 BS 10 Table H and ANSI 300

DN15 - DN50 JIS 10, JIS 16 and ANSI 150

Available on request: DN15 - DN20 BS 10 Table F

DN15 ANSI 300

6 IM-P100-05 CTLS Issue 17

2.3 Pressure/temperature limits -
DP17, DP17G, DP17R, DP17Y and DP27G

Pressure psi g
0 100 200 D 300
232
200 A B 400
Temperature °C

Temperature °F
150 300
F Steam F
100 saturation 200
50 curve
100
C E
0
0 5 10 15 20 25
Pressure bar g

The product must not be used in this region.

A-D-E Screwed and flanged BS 4504 PN25, ANSI 300, and BS 10 Table H.

A-B-C Flanged ANSI 150.

F-F The DP17G and DP27G are limited to 120 °C.

Note: DP17, DP17G and DP27G have a variable rate conical pressure adjustable spring
fitted providing a downstream pressure range of 0.2 - 17 bar g.
DP17Y has a pressure spring with a range of 0.2 - 3 bar g.
DP17R 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.

Body design conditions PN25

PMA Maximum allowable pressure @ 120 °C (248 °F) 25 bar g (362.5 psi g)

TMA Maximum allowable temperature 232 °C (449.5 °F)

Minimum allowable temperature -10 °C (14 °F)

PMO Maximum operating pressure for saturated steam service 17 bar g (246.5 psi g)

Maximum operating DP17, DP17Y and DP17R 232 °C (449.5 °F)

TMO
temperature DP17G and DP27G 120 °C (248 °F)

Minimum operating temperature 0 °C (32 °F)

Note: For lower operating temperatures consult Spirax Sarco.

PMX Maximum differential pressure is limited to the PMO

Designed for a maximum cold hydraulic test pressure of: 38 bar g (551 psi g)

Note: With internals fitted, test pressure must not exceed: 25 bar g (362.5 psi g)

IM-P100-05 CTLS Issue 17 7

2.4 Sizes and pipe connections - DP17E
DN15LC (not available for type DP17G), DN15, DN20, DN25, DN32, DN40 and DN50.
Screwed BSP (BS 21 parallel) or NPT (DN15 to DN25 only).

DN15 - DN50 BS 4504 PN16 and PN25

Standard flanges:
DN25 - DN50 BS 10 Table H and ANSI 300

DN15 - DN50 JIS 10, JIS 16 and ANSI 150

Available on request: DN15 - DN20 BS 10 Table F

DN15 ANSI 300

2.5 Pressure/temperature limits - DP17E

Pressure psi g
0 100 200 300
232
200 400
Temperature °C

Temperature °F
150 300
100 200
50
100
0
0 5 10 15 20 25
Pressure bar g

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.

Body design conditions PN25

PMA Maximum allowable pressure @ 120 °C (248 °F) 25 bar g (362.5 psi g)

TMA Maximum allowable temperature 232 °C (449.5 °F)

Minimum allowable temperature -10 °C (14 °F)

PMO Maximum operating pressure including saturated steam service 10 bar g (145 psi g)

TMO Maximum operating temperature 190 °C (248 °F)

Minimum operating temperature 0 °C (32 °F)

Note: For lower operating temperatures consult Spirax Sarco.

PMX Maximum differential pressure is limited to the PMO

Designed for a maximum cold hydraulic test pressure of: 38 bar g (551 psi g)

Note: With internals fitted, test pressure must not exceed: 25 bar g (362.5 psi g)

8 IM-P100-05 CTLS Issue 17

3. Installation
Note: Before actioning any maintenance programme 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
DP17, DP17G and DP27G (Fig. 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 (3 - 247 psi).

DP17Y (Fig. 1)
The DP17Y is supplied as the DP17, but has a lower rate pressure adjustment spring for a
downstream pressure range of 0.2 - 3 bar (3 - 44 psi).

Pressure setting adjustment screw

Lock-nut

Pressure adjustment spring

Internal pressure control

pipe assembly

Alternative recommended
downstream pressure control
pipe connection (refer to
Section 3.8, page 14)

Fig. 1 DP17, DP17G and DP17Y

IM-P100-05 CTLS Issue 17 9

DP17E
The DP17E (Fig. 2) is supplied as for the DP17 with a control spring but the maximum
pressure is limited to 10 bar g (145 psi 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.

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.

Solenoid valve

Fig. 2 DP17E

10 IM-P100-05 CTLS Issue 17

DP17R
The DP17R (see Fig. 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 (10 psi 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 in Fig. 4. The air inlet connection is suitable for 6 mm
O/D copper tube. The maximum reduced pressure available through the DP17R is
15 bar g (218 psi g). Typical installation is shown in Fig. 9, page 17.

Fig. 3 DP17R

IM-P100-05 CTLS Issue 17 11

3.2 Fitting (Figs. 4, 5 and 6)
The valve should always be fitted in a horizontal pipeline with the main diaphragm chamber
below the line (Fig. 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 (Fig. 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 Fig. 6.

Pressure
Strainer with 100 mesh control Safety Discharge
Separator stainless steel screen pipe valve pipe Small bore
Pressure drain
reducing valve

Steam
supply
Spiratec 0.9 m, (3 ft) or 15 pipe
sensor diameters clear on either side
chamber Ball valve See Section 3.6, page 13.

Downstream isolating valve to

provide no-load conditions for
Check setting pressure reducing valve
Strainer valve
DP17 and DP17E Float type
steam trap

Float type Ball valve

steam trap
Alternative for
draining separator

Strainer Sight glass

Separator

Regulator
Compressed
Filter
Compressed air
air

DP17R
Installation for
compressed air Compressed
Fig. 4 Recommended installation (DP17G and DP27G) air trap

12 IM-P100-05 CTLS Issue 17

Fig. 5 Two pressure reducing valves in parallel

Steam supply

] 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 (98 ft/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

] See Section 3.6

Fig. 6 Two pressure reducing valves installed in series

IM-P100-05 CTLS Issue 17 13

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 control pipe

For applications that require closer control, improved stability or maximum capacity condition
the internal pressure control pipe should be replaced by an external pressure control pipe
as follows:

Remove the internal pressure control 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 blanked off using
the plug fitted in the tapping provided on the front of the pilot valve chamber. Into this latter
tapping, fit the brass compression fitting with brass compression ring which is also contained
in the linen bag. 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 control 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 (3 ft) 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 DP17. Where the size
of the reduced pressure main makes it difficult to maintain a fall when entering the top of
the main, the pressure control 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 Bypass
Information regarding bypasses:
It may be necessary to ensure that primary fluid flow continues in the event of the main
control failing. This is often achieved by fitting a bypass around the control valve assembly.
A better option is a duplex valve assembly, installed in parallel with the main valve, as a
manual bypass cannot accurately control pressure/flow/temperature without constant
manual supervision. Conversely, a duplex control station will provide proper control, should
the main valve ever need to be removed.

Although not recommended, if a manual bypass valve is fitted, the bypass valve flow
coefficient (Kvs) should be the same as, or near to that of, the control valve. This means
that the manual valve and control valve could have different connection sizes. The bypass
valve should also be capable of throttling not just isolating, to reduce wear on the valve
when in service and to facilitate manual control.

Ideally, any bypass pipework should be arranged either above or alongside the main
assembly. On steam systems, it should never be below it.

14 IM-P100-05 CTLS Issue 17

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 set pressure is any lower, if whatever reason the safety valve lifts it will
not shut 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

Line or system isolation valves (A), either remotely actuated or manual, should be installed
on the upstream side of the DP17 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 DP17 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 DP17 and where
a control valve is also being used downstream of the DP17, it is recommended that the
safety valve is fitted downstream of the control valve rather than in between the DP17 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 DP17 (B) the intermediate downstream
pipework must be properly trapped (D) to ensure no condensate can buil up on the
downstream side of the DP.

C
A B
A

Fig. 7 DP17 position in relation to other control equipment

IM-P100-05 CTLS Issue 17 15

4. Commissioning
4.1 Setting procedure (Fig. 8 and Fig. 9)
1. Ensure that all connections are properly made and that all valves are closed.

DP17, DP17E, DP17G, DP17Y and DP27G (Fig. 8) DP17R (Fig. 9)

2. Close all valves at reducing valve station, 2. Close all valves at reducing
including valves on bypass line if fitted. valve station, including the valve
on the bypass line, if fitted.
3. Check that adjustment screw is turned fully
anticlockwise until spring is slack. 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.

DP17, DP17E, DP17G, DP17Y and DP27G DP17R

7. Using a 19 mm A/F spanner slowly turn 7. Slowly admit actuating air through the
adjust m e nt sc rew in a c l o c k w i s e pressure regulator until the desired
direction until desired downstream downstream pressure is obtained.
pressure reading is obtained.
Note : To facilitate resetting of the reducing
8. Holding the adjustment screw in position valve it may be desirable to position the
with the spanner tighten down the lock- downstream pressure gauge at a viewpoint
n u t to s e c u r e t h e s et t i n g of t h e close to the air regulator.
adjustment spring,making sure that the If this necessitates fitting the pressure
'C' washer stays in position. 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.

WARNING
Direct injection systems
This product contains a rust inhibitor to protect it against corrosion during
storage. To avoid any possible contamination of your product, after first blowing
down the approach pipework, we recommend that the valve is blown through
thoroughly in order to remove any trace of the inhibitor.

16 IM-P100-05 CTLS Issue 17

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.
2

Optional bypass line (see Section 3.10)

2, 6 3 2, 9
4 4
Steam flow

5 ]

] See Section 3.6 page 13

5
Condensate
return

Fig. 8 Setting procedure sequence DP17, DP17E, DP17G, DP17Y and DP27G

Optional bypass line (see Section 3.10)

3, 7, 8 2, 9
2, 6
4 4
Steam flow

5 ]

5
Condensate
return ] See Section 3.6, page 13

Fig. 9 Setting procedure sequence DP17R

IM-P100-05 CTLS Issue 17 17

5. Maintenance
Note: Before actioning any maintenance programme observe the 'Safety
information' in Section 1.

Warning:
The body gasket (all DP17 derivatives) and actuating chamber gasket (DP17R)
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 chamber assembly.

- Main valve screen.

- Main diaphragms.

- Pilot diaphragms.

Pilot diaphragms
Pilot valve
Body gasket chamber assembly
(see warning above) Main valve screen

Main valve seat

and valve head

Main
diaphragms

18 IM-P100-05 CTLS Issue 17

To renew or change the control spring DP17 2
It is not necessary to isolate the valve in order to change
the spring. 1

3
1. Release the lock-nut. 4
2. Turn the adjustment screw anticlockwise. Ensure there
is no compression on the pressure adjustment spring.

3. For the DP17 and derivatives only - Slide out the

'C-shape' washer.

4. Remove the cover. 5

5. For the DP17 - Remove the pressure adjustment spring

and top plate.
For the DP27G - Firstly undo the 4 off spring housing
securing nuts and remove the spring housing. Then
remove the pressure adjustment spring and the top
spring plate.

6. Reassemble in reverse order.

DP17

To renew the pilot valve assembly

DP17, DP17E, DP17G , DP17Y and DP27G 8
Isolate the pressure reducing valve and zero the pressure.
Follow Steps 1 to 5 then proceed.
DP17R
Isolate the actuating air supply and zero the pressure.

7. Unscrew the unions and release the pipework.

7
8. DP17, DP17E, DP17G and DP17Y 7
Unscrew the spring housing nuts and remove the spring
housing, bottom spring plate and diaphragms.
DP27G 1
DP27G
Undo the 4 off spring housing securing nuts and
remove the spring housing. Then removethe pressure
adjustment spring, top spring plate, bottom spring plate
and diaphragms.

DP17R 4
Unscrew the securing nuts and remove the air control
block and diaphragms.
5

7
7

IM-P100-05 CTLS Issue 17 19

9. Remove the pilot valve housing.

10. Ensure that the main valve return spring is still in position. Any trapped dirt or scale
should be removed from the pilot valve assembly. If appropriate, the complete pilot
valve chamber assembly can be refitted following Steps 14 to 21. If necessary, the
complete pilot valve chamber assembly should be replaced as follows:

Note: The pilot valve assembly is no longer available as a standard spare. Because of
the difficult process described in Step 13, it has now been discontinued. The complete
pilot valve chamber assembly is the recognised spare. However for customers with pilot
valves only still in stock, these can be used by following Steps 11-13. This assembly
contains 2 off PTFE seals. 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.

11. Unscrew and remove the pilot valve assembly (22 mm A/F)

12. Screw the new pilot valve into the housing. Torque 45 - 50 N m (33 - 37 lbf ft).

13. Check that there is a very slight clearance between the top of the plunger and a straight
edge placed across the diaphragm location recess. (N.B. Because of production
tolerances the plunger is supplied slightly longer than is always required and it will
generally be necessary to grind or machine material off the top end to give the correct
length). After machining make sure the sharp edges are removed from the top of the
plunger as these could damage the diaphragm.

14. Remove the screen and clean. Ensure that the gasket faces are clean.

15. Ensure that the main valve return spring is still in position.

16. Fit new gasket.

17. Replace the screen. Assemble the pilot valve housing.

18. 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.

19. DP17, DP17E, DP17G, DP17Y and DP27G

Replace bottom spring plate.

20 IM-P100-05 CTLS Issue 17

20. DP17, DP17E, DP17G, DP17Y and DP27G
Assemble the spring housing and tighten the nuts to the recommended torques shown
in Table 1, page 21.

DP17R
Assemble the air control block and tighten the nuts to the recommended torques shown
in Table 1, page 21.

21. Refit the pipework and retighten the unions to ensure a steam tight seal.

Bring the valve back into commission by following as many Steps as are necessary in
Section 4, page 16.

20

10

19
18

21 17
21
11
16

14 17 14

13
12
15

Table 1
Recommended tightening torques for pilot valve chamber nuts
Size of valve Nut size Tightening torques
½", ¾", 1" M10 40 - 50 N m (30 - 37 lbf ft)
DN15, DN20, DN25 and DN32
DN40 and DN50 M12 45 - 55 N m (33 - 41 lbf ft)

IM-P100-05 CTLS Issue 17 21

To clean the strainer screen
DP17 shown
DP17, DP17E, DP17G, DP17Y and DP27G
Isolate the pressure reducing valve and zero the
pressure. Follow Steps 1 to 5 then proceed.
23
DP17R
Isolate the actuating air supply and zero the 24
pressure.

22. Unscrew the unions and release the

pipework. 25

23. Unscrew the nuts. Note that this has already 22 22

been actioned under step 5 for the DP27G.

24.DP17, DP17E, DP17G, DP17Y and DP27G

Remove the pilot valve housing; complete
with the spring housing assembly.

DP17R
Remove the pilot valve housing, complete DP17 shown
with air control block.

25. Remove the main valve screen and clean.

26. Ensure that the gasket faces are clean.

27. Check that the main valve return spring is in

position.
30
28. Fit a new gasket.

29. Replace the main valve screen.

29
30. DP17, DP17E, DP17G and DP17Y 31 31
28
Assemble the pilot valve housing complete
with the spring housing assembly and tighten
the nuts to the recommended torques shown 26
in Table 1, page 21. 27
DP17R
Assemble the pilot valve housing complete
with the air control block and tighten the
nuts to the recommended torques shown in
Table 1, page 21.

31. Refit the pipework and retighten the unions

to ensure a tight seal.

Bring the valve back into commission by

following as many steps as are necessary in
Section 4, page 16.

22 IM-P100-05 CTLS Issue 17

To renew pilot valve diaphragms
35
DP17, DP17E, DP17G, DP27G and DP17Y 32
Isolate the pressure reducing valve and zero the
pressure. Follow Steps 1 to 5 then proceed.

DP17R
Isolate the actuating air supply and zero the
pressure.

32. DP17, DP17E, DP17G, DP17Y and DP27G 34

Unscrew the spring housing nuts and remove
the spring housing, bottom spring plate and old 33
diaphragms.

DP17R
Unscrew the securing nuts and remove the air
control block and old diaphragms.

33. Ensure that all contact faces are cleaned. New

diaphragms should be fitted such that the 37
precoated sealant (which is only applied to one
diaphragm) faces down contacting the sealing
face of the diaphragm chamber.

34. DP17, DP17E, DP17G, DP17Y and DP27G

Replace the bottom spring plate.

35. DP17, DP17E, DP17G, DP17Y and DP27G 36

Assemble the spring housing and tighten the
nuts to the recomended torque shown in Table
1, page 21.

DP17R
Assemble the air control block and tighten the
nuts to the recommended torques shown in 39
Table 1, page 21.

Bring the valve back into commission by following

as many Steps as are necessary in Section 4,
page 16.
38

IM-P100-05 CTLS Issue 17 23

40. Replace the diaphragm plate and
41
pushrod assembly and loosely fit the
lower diaphragm chamber on the two
bolts either side of the union connection
to locate the spigot in the recess.
40

41. Bring the two new diaphragms together

(where precoated sealant is applied
this should face outwards) and slide
into position.
If the diaphragms are not renewed, but 43
42
cleaned only, care must be taken to
replace the diaphragms in their original
order.

42. Push the lower diaphragm chamber

home to locate in the recess and refit
the M12 nuts and bolts.
Progressively and evenly tighten to a
torque of 80 - 100 N m (59 - 74 lbf ft).

43. Retighten the long union nut to ensure

a steam tight seal.

Bring the valve back into commission by

following as many Steps as are necessary
in Section 4, page 16.

To service or renew the main

valve and seat
DP17, DP17E, DP17G , DP17Y and DP27G
45
Isolate the pressure reducing valve and
zero the pressure. Follow Steps 1 to 5 then
proceed.

DP17R
Isolate the actuating air supply and zero 46
the pressure.

44. Unscrew the unions and release the

pipework.

45. Unscrew the spring housing nuts. 47

44 44
46. DP17, DP17E, DP17G, DP17Y and
DP27G
Re m ove t h e p i l ot va l ve h o u s i n g,
c omplete with the spring housing
assembly.

DP27G shown

24 IM-P100-05 CTLS Issue 17

DP17R 48
Remove the pilot valve housing, complete
with the air control block.

47. Remove the main valve, screen and

clean.

48. Remove the main valve spring and the

main valve head. Clean to remove dirt 50
or scale as is necessary.

49. Remove the main valve seat. Clean and

remove dirt and scale as is necessary.
Examine the faces of the main valve
head and seat. If they are only slightly 49
worn both the main valve head and main
seat may be lapped on a flat plate using
a fine grinding paste.
If either is badly worn or unfit for further
use they will need to be replaced. Clean
to remove dirt or scale as necessary.

DP17G
If there is any wear or damage to the
nitrile face then the head assembly must
be replaced.

50. Refit the valve seat applying jointing

compound to the seating faces and 52
tighten to the recommended torque
shown in Table 2, page 26.
Where a new part has been fitted it will
be necessary to reset the main valve
pushrod to give the correct valve lift.
To do this it is necessary to expose
the main diaphragm plate and pushrod
assembly.

51. Undo the long nuts and pull away. 51

52. Undo the M12 nuts and bolts.

53. Drop away the lower diaphragm chamber,

the two diaphragms, diaphragm plate
and the pushrod assembly.

53

IM-P100-05 CTLS Issue 17 25

Table 2 Recommended tightening torques for the main seat
Size of valve Width across flats Tightening torques

½" and ½" LC

30 mm A/F (External) 110 - 120 N m (81 - 89 lbf ft)
DN15 and DN15LC

¾" and DN20 36 mm A/F (External) 140 - 150 N m (103 - 111 lbf ft)

1" and DN25 19 mm A/F (Inside) 230 - 250 N m (170 - 184 lbf ft)

DN32 24 mm A/F (Inside) 300 - 330 N m (221 - 243 lbf ft)

DN40 30 mm A/F (Inside) 450 - 490 N m (332 - 361 lbf ft)

DN50 41 mm A/F (Inside) 620 - 680 N m (456 - 502 lbf ft)

54. Refit the pushrod assembly.

55. Refit the main valve head, making sure that the valve locates on the seat.

56. Check the valve lift shown in Table 3 using a depth gauge.

Depth gauge
59
57

55

58
56
Table 3
Size of valve Valve lift

DN15LC and ½" LC 2.5 mm (0.098")

DN15 and ½" 2.5 mm (0.098")

DN20 and ¾" 2.5 mm (0.098")

54 DN25 and 1" 3.0 mm (0.118")

DN32 3.5 mm (0.138")

56
DN40 4.5 mm (0.177")

DN50 5.0 mm (0.197")

Adjust if necessary by screwing the pushrod

in or out of the diaphragm plate.

26 IM-P100-05 CTLS Issue 17

 61
57. Thoroughly clean the lower diaphragm
chamber making sure that the contact 60
faces are clean.

58. Replace the diaphragm plate and

pushrod assembly and loosely fit the
lower diaphragm chamber on to the two
bolts either side of the union connection
to locate the spigot in the recess.

59. Refit the diaphragms in exactly the same

way as when dismantled.

60. Push the lower diaphragm chamber

home to locate in the recess and refit 63
the M12 nuts and bolts. Progressively 64
and evenly tighten to a torque of 75 N m.

61. Retighten the long union nut to ensure

a steam tight seal.
62
62. Refit the main valve head.

63. Replace the main valve return spring.

64. Fit a new gasket.

65. Replace the screen.

66. DP17, DP17E, DP17G, DP17Y and

DP27G
Assemble the pilot valve housing
c omplete with the spring housing
assembly and tighten the nuts to the
recommended torques shown in Table
1, page 21. 66

DP17R
Assemble the pilot valve housing
complete with the air control block and
tighten the nuts to the recommended
torques shown in Table 1, page 21.

67. Refit the pipework and retighten the

unions to ensure a tight seal.

Bring the valve back into commission by 64 67

67
following as many Steps as necessary in
Section 4, page 16.

DP27G shown

IM-P100-05 CTLS Issue 17 27

To service or renew solenoid valve
DP17E
Depressurize the valve and turn off the electrical power supply.

68. Undo the retaining nut and slip the entire solenoid enclosure off the solenoid base and
sub-assembly or plugnut/core tube sub-assembly.

69. Unscrew the bonnet or solenoid base sub-assembly and remove the core spring, core
assembly and body gasket.
All the parts are now accessible for cleaning or replacement. Replace worn or damaged
parts with a complete Spare parts kit (item 'W', pages 30 and 31) for best results.

70. Reassemble in reverse order paying careful attention to exploded views provided.

71

68
72

70

69

CAUTION
The solenoid must be fully reassembled
as the housing is part of, and completes
the magnetic circuit.

Coil replacement
Switch off the electrical power supply and
disconnect the coil lead wires.

71. Undo the retaining nut.

72. Slip the washer, insulating washers and coil

of f the solenoid base sub - assembly.
Reassemble in reverse order (see the
CAUTION above).

28 IM-P100-05 CTLS Issue 17

6. Spare parts
Interchangeability of spares
The following table shows how in certain sizes some parts are interchangeable. For example
in the line headed 'Main diaphragm' the diaphragm used in the screwed valves ½" and ¾"
is common to these sizes by the letter 'a', the letter 'c' indicates that one diaphragm is
common to the DN40 and DN50 valves. All spares are interchangeable with the DP17T and
where marked † are interchangeable with the 37D temperature control.**

** Note: This does not apply to DP17G soft seat pilot valve or main valve assemblies.

Screwed Flanged
*** ***

Size DN ½"LC ½" ¾" 1" 15LC 15 20 25 32 40 50

Maintenance kit 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 chamber

a a a a a a a a a b b
assembly

PTFE seals a a a a a a a a a a a

Main valve assembly † a b c d a b c d e f g

Internal strainer † a a a b f f a b c d e

Main valve return spring † a a a a a a a a a c c

Pressure adjustment
a a a a a a a a a a a
spring

Control pipe assembly † a a a b f f a b c d e

Balance pipe assembly a a a b f f a b c d e

Body gasket † a a a a a a a a a b b

Set of spring housing

a a a a a a a a a b b
securing studs and nuts

Set of main body studs

† a a a a a a a a a b b
and nuts

Set of diaphragm
† a a a a a a a a a b b
securing bolts and nuts

Pushrod and main

diaphragm plate a a a b a a a b b c c
assembly

*** Not available for DP17G

IM-P100-05 CTLS Issue 17 29

Spare parts
The spare parts available are shown in solid outline. Parts drawn in a grey line are not
available as spares.

Available spares

Maintenance kit
A stand-by set of spares for general maintenance purposes and covers all spares marked *

Main diaphragm (2 off) * A

Pilot diaphragm (2 off) * B

Pilot valve chamber assembly (8 pieces) * C, C1

Main valve assembly K, L

Internal strainer * M

Main valve return spring * N

DP17, DP17E,
Pressure adjustment spring 0.2 to 17 bar (3 to 247 psi)
DP17G and DP27G O
(Not required for DP17R)
DP17Y 0.2 - 3 bar (3 - 44 psi)

Control pipe assembly P

Balance pipe assembly * Q

Body gasket (3 off) * R

Set of spring housing/actuating chamber cover securing studs and nuts (set of 4) S

Set of main body studs and nuts (set of 4) T

Set of diaphragm securing ½" - DN32 (set of 10)

Valve sizes V
bolts and nuts DN40 and DN50 (set of 12)

Pushrod and main diaphragm plate assembly Y

Type DP17E only

Solenoid valve complete W

Replacement coil X1

Valve seat and core assembly X2

How to order spares

Always order spares by using the description given in the column headed 'Available spares'
and state the size and type of the pressure reducing valve.

Example:
1 - Main valve assembly for a Spirax Sarco 1" DP17 pilot operated pressure reducing valve.

30 IM-P100-05 CTLS Issue 17

 DP17 DP27G DP17R

Solenoid valve complete

Pilot valve chamber assembly

B
Q
C1 X1
W
C
R

P1 X2
P

T
N R
V
T
Main valve assembly

K
L

A
Y

M V

IM-P100-05 CTLS Issue 17 31

7. Fault finding
7.1 Preliminary procedure
Before undertaking the following fault finding procedure, ensure that the valve has been
isolated and that upstream and downstream pressures are zero. Possible fault checks are
given in a logical order below.

7.2 Downstream pressure zero or too low

If downstream pressure drops below set pressure or is zero, check the following:
1. No high pressure steam reaching the pressure reducing valve. Check that steam is
turned on and that the strainer is clear. (To assist with commissioning and fault finding
it is recommended to fit an upstream pressure gauge).

2. Pressure adjustment spring broken.

3. Pipe assembly (Item 'P' on page 31) blocked. Remove by uncoupling the union nuts and
blow through to clear obstruction.

4. Control orifice blocked. Unscrew from the outlet port and clear out obstruction. For
identification this coupling has a groove around the hex.

5. Main diaphragms fractured. Replace the diaphragms following Steps 36 to 43.

6. Pilot valve plunger too short. Check as Section 5 Step 13.

7. Valve capacity insufficient for downstream conditions.

a) Check that the upstream pressure is correct. If it is low, the capacity of the valve
will be reduced.

b) Ensure that the pressure control pipe is fitted as recommended in Section 3.8 and
if necessary fit an external pressure control pipe as described. If the downstream
pressure is still too low, then a larger valve with more capacity is required.

7.3 Downstream pressure too high

If the pressure on the downstream side of the pressure reducing valve has risen above the
required set pressure check the following:
1. Downstream pressure control pipe blocked. Dismantle and blow through.

2. Control orifice (item 'P1' on page 31) blocked. Unscrew the pipework from the side of
the body and clean out. For identification this coupling has a groove around the hex.

3. Pilot valve diaphragms fractured. Check and replace (see page 31).

4. Pilot valve or pilot valve plunger is sticking. Follow Steps 7 to 11.

5. Main valve not seating. Check as page 31.

6. Main valve pushrod sticking. Follow Steps 36 to 43.

7. Pilot valve plunger too long. Check as Section 5 Step 13.

8. Pilot valve not seating. Refer to procedure on page 31.

32 IM-P100-05 CTLS Issue 17

7.4 Hunting
Hunting may coincide with variations in steam load. If this is the case, the following checks
should be made before dismantling the valve:
1. Check that the upstream pressure is stable. If the pressure drops during full-load
conditions, 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 the possibility of not maintaining the downstream pressure
during full-load conditions.

2. If the upstream pressure is correct, and stable, set the valve on dead-end conditions.
Apply full-load to the valve. If the downstream pressure drops excessively during full-load
condition, it is likely that the valve is undersized, in which case it should be replaced.
Once it has been determined that the upstream pressure is correct and stable, and
that the valve is correctly sized, the following check should be carried out on the valve:

3. Steam is very wet. Ensure the valve installation is as recommended in Fig. 4, page 12.

4. The point at which the external pressure control pipe is tapped into the main is in a
turbulent area. Refer to Section 3.8 for guidance.

5. Loose dirt in the pipe assembly (Item 'P' on page 31). Remove the pipe assembly. Blow
through to clear.

6. Pilot valve or pilot valve plunger is sticking. Follow Steps 7 to 11.

7. Main valve pushrod sticking. Follow Steps 36 to 43.

8. Pilot diaphragms or main diaphragms overstretched. To replace, see page 31.

IM-P100-05 CTLS Issue 17 33

34 IM-P100-05 CTLS Issue 17
IM-P100-05 CTLS Issue 17 35
36 IM-P100-05 CTLS Issue 17