MIYAWAKI RE20 Manuale utente

1 SPECIFICATIONS AND MARKINGS

WARNING

Be sure not to use this product at higher pressures than the specified maximum allowable

pressure (PMA) or at temperatures

higher than the specified maximum allowable

temperature (TMA).

Main technical specification of the product:

(Check each item to avoid misuse of the product.)

PN16

 Maximum allowable pressure (PMA): 1,6 MPa, 16 bar, 232 psig (@150°C, 302°F)

 Maximum allowable temperature (TMA): 350°C, 662°F (@ 1,1 MPa, 11 bar, 160 psig)

 Maximum operating (inlet) pressure (PMO): 1,5 MPa, 15 bar, 218 psig (@200°C, 392°F)

 Maximum operating temperature (TMO): 350°C, 662°F (@ 1,1 MPa, 11 bar, 160 psig)

 Adjustable Secondary (Outlet) Pressure: 0,05 to 1,6 MPa / 0,5 to 16,0 bar / 7.25 to 232 psig

PN25

 Maximum allowable pressure (PMA): 2,5 MPa, 25 bar, 363 psig (@100°C, 212°F)

 Maximum allowable temperature (TMA): 350°C, 662°F (@ 1,8 MPa, 18 bar, 261 psig)

 Maximum operating (inlet) pressure (PMO): 2,2 MPa, 22 bar, 319 psig (@250°C, 482°F)

 Maximum operating temperature (TMO): 350°C, 662°F (@ 1,8 MPa, 18 bar, 261 psig)

 Adjustable Secondary (Outlet) Pressure: 0,05 to 1,6 MPa / 0,5 to 16,0 bar / 7.25 to 232 psig

 (For lower or higher secondary pressure setting than indicated contact our office or local representative)

 Maximum Pressure Reducing Ratio: 25 : 1

 Minimum Differential Pressure: 0,05 MPa / 0,5 bar / 7.25 psi

 Connection & Size: Flanged DIN-EN 1092-1 and ASME B16.5 –DN15 –DN200 (½” – 8”)

(For socket weld, butt-weld or screwed connections contact our office or local representative)

 Flow direction: Shown by an arrow.

 Body material: Ductile cast iron 0.7040

Check the Pressure-Temperature Rating of the product.

Don’t use it beyond the pressure and temperature limits of the table !!

PN Body

material

Temperature °C

-10 …+50 100 150 200 250 300 350 400 450 500 530

Pressure MPa

16 0.7040 1,6 1,6 1,6 1,5 1,4 1,3 1,1

25 0.7040 2,5 2,5 2,4 2,3 2,2 2,0 1,8

1.0619

4,0

3,7

3,5

3,1

2,8

2,6

2,4

2,3

1.4408

4,0

3,7

3,4

3,1

2,9

2,8

2,7

2,6

1.0619

6,3

5,9

5,5

4,9

4,5

4,1

3,8

3,6

1.7357

6,3

6,2

5,7

5,3

5,0

4,8

3,8

2,2

100

1.0619

10,0

9,3

8,7

7,8

7,1

6,4

6,0

5,8

1.7357

10,0

9,8

9,1

8,4

8,0

7,6

6,1

3,5

DIMENSIONS

3 CONSTRUCTION DETAILS

Parts-

No.

Description

Parts-

No.

Description

Body

Cooling cylinder

Valve cover

Bolt

Gasket

Hexagon nut

Stud bolt

Control housing

Hexagon nut

Bonnet

Valve seat

Socket head screw

Cone

Pressure spring

Cone rod

Spring plate

Control piston

Adjusting screw

O-Ring

Hexagon nut

Locking screw

Guide sleeve

Gasket

Size Dimensions

(

)

Dimensions

& Weights

Weight

(

)

DN PN16-40 H

Kvs

value 0.7040 1.0619 1.4408

PN63-100

100

125

150

200

100

113

140

154

210

235

285

1,8

3,2

5,0

7,9

13,0

20,0

34,0

51,0

80,0

130,0

180,0

320,0

11,4

12,5

14,5

16,0

35,0

39,5

52,5

68,0

150,0

180,0

330,0

12,0

13,0

16,0

18,0

37,5

43,0

58,0

77,0

155,0

190,0

385,0

12,0

13,0

16,0

18,0

37,5

43,0

58,0

77,0

155,0

190,0

385,0

130

150

160

180

200

230

290

310

350

210

230

260

300

340

380

430

400

480

600

410

586

615

733

762

715

720

950

5 2

4 INSTALLATION

WARNING

Pay very careful attention when working in hazardous environments. There is a risk of

explosion and the possibility of dangerous gases leaking. Always check whether the pipeline

contains flammable, high pressure or high temperature materials before starting to work.

 Make sure that isolation valves are installed on both the upstream and downstream

lines.

CAUTION

Before installing the product, open both isolation valves and the bypass valve, if one exists, to

blow out any debris or dirt inside the pipeline. After blowing out the line, before starting to

work, close the isolation valves and allow time for the temperature to drop to a safe working

temperature.

 When installing the product, be sure to leave clearance for maintaining it.

Installation Process

 Remove the dustproof seals covering both connections (if existing).

 Check the flow direction indicated on the side of the body.

 The pressure reducing valve should be installed in a horizontal pipe

line with the cooling cylinder (No. 14) turned downwards, with

suitable bypass and isolating valves.

 To prevent water hammer and vibrations caused by incoming

condensate it is necessary to install a steam trap before the pressure

reducing valve.

 If you expect the average flow velocity to rise above 30m/sec, it is recommended to increase

the size of the pipe on the downstream side.

 In case the pressure reducing ratio exceeds 25 : 1 , the pressure reduction is to be made in two

steps. In that case, a distance of at least 3 meters has to be kept between the two pressure

reducing valves.

 The distance between the pressure reducing valve and a solenoid valve must be of at least 3

meters, if a solenoid valve with on/off function is installed upstream or downstream of the

pressure reducing valve. Otherwise, the pressure reducing valve may not function in a stable

way while the valve is opening or closing.

 If a control valve is installed downstream of the pressure reducing valve, the distance between

the pressure reducing valve and the control valve must be of at least 2 meters. The disregard of

this recommendation may cause an unstable function of the pressure reducing valve as well.

 To prevent an unusual rise of the secondary pressure a safety valve has to be installed to

protect the steam consuming equipment.

down

 The pipe in which the pressure reducing valve is installed, must be fixed so that the weight and

the vibration of the pipe do not directly influence the pressure reducing valve.

 Blow down the piping that leads to the PRV’s inlet from any dirt and scale before the first start-

up of the pressure reducing valve. This is particularly important in case of the start-up of the

pressure reducing valve after a long time of shut-down.

 Before a long shut-down of the pressure reducing valve the condensate must be completely

discharged from the pipe. Furthermore the stop valves before and behind the pressure reducing

valve have to be closed.

 The distance between the pressure reducing valve and a downstream pressure gauge should be

of at least 1 meter.

 The length of the straight section of the upstream piping and the length of the straight section

of the downstream piping should be each at least 10 pipe diameters.

 The steam trap and the pressure reducing valve should both be protected with a strainer. The

strainer should be installed in such a way that the screen will point sidewards to avoid the

accumulation of condensate in the area of the screen.

 If you insulate the pressure reducing valve, do not insulate the cooling cylinder !!! The

insulation of the cooling cylinder prevents the built-up of condensate inside the cooling cylinder,

which is protecting the O-Rings. If there will be no condensate inside the cooling cylinder, the

O-Rings may be damaged !

Adjustment

The pressure reducing valve is usually preadjusted at the factory in accordance with the

instructions of the customer. As the real steam consumption and operating pressure may differ a

readjustment after installation under operating conditions is recommendable.

 After the installation and before the adjustment of the pressure reducing valve close the stop valves

before and behind the pressure reducing valve and open the bypass to remove all condensate and

dirt from the pipe.

 Close the bypass valve.

 Open the stop valve downstream slightly. Then open the stop valve upstream slowly.

 Now, open the stop valve downstream completely and check the set pressure.

 To readjust the downstream pressure release the locking nut (No. 23). To increase the downstream

pressure turn the adjusting screw (No. 22) clockwise until the required pressure is reached. To

reduce the downstream pressure turn the adjusting screw counterclockwise until the required

pressure will be reached. After setting the downstream pressure, tighten the locking nut again.

 In case of a shut-down of the equipment the stop valve downstream must be closed at first. The

stop valve upstream is to be closed as a second step. When the equipment will start up again open

the stop valve downstream at first and then open the stop valve upstream slowly.

5 MAINTENANCE

CAUTION

 When replacing parts, make sure the replacement parts are supplied by Miyawaki.

 Assemble and disassemble the valve after the internal pressure becoming the same as

the atmospheric pressure, and the surface temperature of the valve dropping enough

to prevent burning and serious injuries.

5.1. Remove the PRV from the pipe line

5.2. Fix the valve in a vice with the spring bonnet and adjust screw

showing upwards.

5.3. Untighten the locking nut (23) and unscrew it. Then turn the

adjusting screw (22) counterclockwise until the screw is moving

easily (no pressure exerting to the spring).

5.4. Untighten the 4 socket head screws (19) and remove them. Now

take off the bonnet (18) from the valve.

5.5. Remove the Spring plate (21) and the spring (20) from the valve.

5.6. Remove the valve from the vice and fix it again so that the flanges are showing upwards.

Untighten the hexagon nuts (5 - wrench size 17 mm) and remove the valve cover (2) from

the body. Remove also the cover gasket (3) and replace it by a new one.

5.7. Now again turn the valve to the former position when the cooling cylinder is showing

upwards. Untigten the locking screw with an impact driver (size 19 mm). After loosening

the locking screw (11) screw it out.

5.8. Caution !!

For DN15-DN40 (1/2”- 1 ½”) there is placed a small metal ring below the locking screw. Take

it out. Under the metal ring there are located small balls (12 pcs.). They are keeping the

cone rod (8) in its position. Remove these small balls carefully by turning the valve 180°. Pay

attention that the balls will not be lost.

5.9. Now remove the cone rod (8) from the valve body.

5.10. Remove the control piston (9) from the control housing (17). Replace the O-Ring (10) by a

new one.

5.11. Replacement of the gaskets between the cooling cylinder and body and between the cooling

cylinder and control housing

Untighten the hexagon nuts (16 - wrench size 15 mm) and unscrew them. Take off the valve

body from the cooling cylinder (14) and remove the cooling cylinder from the control

housing (17). Take off the guide sleeve (12) from the cooling cylinder. Check and clean the

openings in the guide sleeve. Replace the gaskets (13 –3 pcs.) by new ones.

5.12. Now reassemble the valve in the opposite way.

6 TROUBLESHOOTING

Problem

Cause

Solution

The downstream pressure

doesn't meet the set value.

It is too low.

Pressure was set incorrectly.

Turn the adjusting screw to correct the

setting of the secondary pressure.

The upstream stop valve is closed .

Open the valve.

The downstream stop valve is closed .

Open the valve.

The pressure gauge does not work

properly.

Replace the pressure gauge.

The steam amount upstream is too

small.

Check the steam amount by using a

bypass valve.

Insufficient capacity of the pressure

reducing valve. The size of the valve is

too small.

Check the real steam amount and the

capacity of the valve.

The screen of a strainer installed on

the inlet side of the pressure reducing

valve is plugged.

Clean the screen.

The O-Ring No.10 is leaking.

Replace by a new one.

The gasket of the valve cover (3) is

leaking.

Replace by a new one.

The downstream

pressure

exceeds the set pressure.

Pressure was not set correctly.

Turn the adjust screw to correct.

Inlet and outlet were installed the

wrong way round.

Install correctly according to the flow

direction.

The downstream stop valve is closed.

Open the stop valve.

The surface of the seat and/or valve is

damaged. The valve cannot close and

regulate the downstream pressure.

Check the valve and seat and judge

which parts must be replaced.

The openings in the guide sleeve (12)

are plugged. Steam cannot enter the

cooling cylinder.

Disaasemble the valve and clean the

guide sleeve.

The gaskets No. 13 are leaking.

Replace by new ones.

The secondary pressure is

fluctuating.

The inlet pressure is fluctuating.

Check the operating conditions on the

inlet side.

The steam consumption is fluctuating

strongly.

Check the downstream operating

conditions.

The steam consumption is exceeding

the capacity of the valve from time to

time.

Check the operating conditions and

select another size of the valve, if

necessary.

7 WARRANTY

7.1 Warranty period

The warranty period shall last 18 months from the date of product delivery, but not more than 12

months after the date of installation.

7.2 Details of the warranty

If the product stops working correctly within the warranty period, we will repair or

replace the product free of charge if the cause of the trouble is not one of the

following items:

 The precautions described in this manual were not observed.

 User's errors or mistakes such as an inappropriate installation or incorrect handling, or an

excessively large impact caused by dropping

 Problems caused by devices or equipment other than ours, or a disallowed use

environment

 When a repair or modification has been performed by anyone else than us or people who

are authorized to make such repairs

 Intrusion of salt or other substances that promote significant rust or corrosion or problems

from fluids that contain the same substances

 Extremely worn packing, gaskets, or other parts

 Attachment or accumulation of foreign objects in the pipe, such as dust and scale

 Problems from fires, natural disasters, or other force majeure which is not our

responsibility

7.3 Warranty limitation

The remedy available under the warranty shall not exceed the sales price of the products

delivered, for any cause whatsoever.

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