Yoshitake GPK-2001 Manuale utente

■EPDT-098a■

Model GPK-2001, GPK-2003

PRESSURE REDUCING VALVE

Installation & Operation Manual

Thank you very much for choosing the Yoshitake’s product. To ensure the correct and safe use

of the product, please read this manual before use. This manual shall be kept with care for

future references.

―――――――The following safety symbols are used in this manual. ――――――――

Warning

Caution

Contents

1. Specifications ····························································1~2

2. Dimensions and Weights ·············································2~3

3. Operation ·································································4~6

4. Nominal Size Selection Method

4.1 Specifications selection chart ····································· 7

4.2 Safety valve setting pressure chart ······························ 7

4.3 Characteristics chart················································· 8

4.4 Nominal size selection chart······································· 9

4.5 Nominal size selection calculation formula····················10

5. Installation

5.1 Precautions for installation ········································11

5.2 Installing accessories···············································11

5.3 Piping before and after the pressure reducing valve········12

5.4 Example of piping ···················································13

6. Operating Procedure

7.1 Precautions for operation··········································14

7.2 Adjustment procedures ············································14

7. Maintenance Procedure

8.1 Troubleshooting··················································· 15~16

8.2 Precautions for maintenance and inspection ·················16

8.3 Disassembly······················································· 16~17

8.4 Precautions during reassembly ··································17

8.5 Exploded drawing ················································ 18~19

Warranty Information

This symbol indicates a potentially hazardous situation that, if not

avoided, could result in death or serious injury.

This symbol indicates a hazardous situation that, if not avoided, may

result in minor or moderate injury. (“Caution” may also be used to

indicate other unsafe practices or risks of property damage.)

■EPDT-098a■

-1-

1. Specifications

[Models]

Model

Nominal pressure

Connection

Nominal size

The ratio of control pressure

to setting pressure

GPK-2001

2.0 MPa

Screwed

15 ~ 50A

1: 1

Flanged

15 ~ 100A

1.0 MPa

GPK-2003

2.0 MPa

Screwed

15 ~ 50A

1: 3.5

Flanged

15 ~ 100A

1.0 MPa

[Specifications]

Model

GPK-2001

GPK-2003

Reduced pressure

sensing method (*1)

External sensing

Connection

JIS Rc screwed, JIS 20K RF flanged, JIS 10K FF flanged

Nominal size

15 ~ 50A (Screwed), 15 ~ 100A (Flanged)

Fluid

Steam

Inlet pressure

0.1 ~ 2.0 MPa (JIS Rc, JIS 20K)

0.1 ~ 1.0 MPa (JIS 10K)

0.25 ~ 2.0 MPa (JIS Rc, JIS 20K)

0.25 ~ 1.0 MPa (JIS 10K)

Reduced pressure

0.05 ~ 0.9 MPa (JIS Rc, JIS 20K)

0.05 ~ 0.85 MPa (JIS 10K)

0.2 ~ 1.4 MPa (JIS Rc, JIS 20K)

0.2 ~ 0.85 MPa (JIS 10K)

85% or less of inlet pressure (gauge pressure)

System air pressure

Refer to Standard “Loading pressure - Set pressure” chart line.

Min. differential

pressure

0.05 MPa

Max. pressure reducing

ratio

20: 1

10: 1

Max. temperature

220 °C

Valve seat leakage

0.01% or less of rated flow

Material

Body

Ductile Cast iron

Main valve

Stainless steel

Main valve seat

Stainless steel

Pilot valve

Stainless steel

Pilot valve seat

Stainless steel

Diaphragm

Stainless steel

(*1) For reduced pressure sensing method, internal sensing method valves will be

available upon request.

Caution

(1) Please collate with attached nameplate and specification of ordered model.

* Please consult factory in case they do not match each other.

■EPDT-098a■

-2-

[Standard “Loading Pressure - Set Pressure” chart Line]

Basically, the set pressure to the loading air

pressure is as shown in the chart above. The

set pressure is slightly different depending on

the working conditions. For the actual use,

adjust loading air pressure suitable for the

necessary set pressure.

2. Dimensions and Weights

[GPK-2001]

•The structure differs for nominal sizes 50A to 100A.

(mm)

Nominal

Size

Screw (JIS Rc)

Flanged (JIS 20K RF)

Weight

（kg）

Weight

（kg）

15A

Rc 1/2

150

335

170

200

14.0

146

335

170

200

15.5

20A

Rc 3/4

150

335

170

200

14.0

146

335

170

200

16.0

25A

Rc 1

160

341

175

226

18.5

156

341

175

226

21.0

32A

Rc 1-1/4

180

371

192

226

21.5

176

371

192

226

24.0

40A

Rc 1-1/2

180

371

192

226

21.5

196

371

192

226

24.5

50A

Rc 2

230

435

216

276

33.0

222

435

216

276

36.0

65A

―――

－

―

―――

282

489

251

352

64.5

80A

―――

－

―

―――

302

512

264

352

71.5

100A

―――

－

―

―――

342

595

321

401

111.0

* Different Length (L) and Weight values apply for JIS 10K FF.

* Other standard connections are available upon request.

(Screwed)

(Flanged)

■EPDT-098a■

-3-

[GPK-2003]

•The structure differs for nominal sizes 50A to 100A.

(mm)

Nominal

Size

Screw (JIS Rc)

Flanged (JIS 20K RF)

Weight

（kg）

Weight

（kg）

15A

Rc 1/2

150

353

170

200

17.5

146

353

170

200

19.0

20A

Rc 3/4

150

353

170

200

17.5

146

353

170

200

19.5

25A

Rc 1

160

359

175

226

22.0

156

359

175

226

24.5

32A

Rc 1-1/4

180

389

192

226

25.0

176

389

192

226

27.5

40A

Rc 1-1/2

180

389

192

226

25.0

196

389

192

226

28.0

50A

Rc 2

230

453

216

276

36.5

222

453

216

276

39.5

65A

―――

－

―

―――

282

507

251

352

68.0

80A

―――

－

―

―――

302

530

264

352

75.0

100A

―――

－

―

―――

342

613

321

401

114.5

* Different Length (L) and Weight values apply for JIS 10K FF.

* Other standard connections are available upon request.

(Screwed)

(Flanged)

■EPDT-098a■

-4-

Fig.1

3. Operation

The pressure reducing valve reduces pressure by the throttling the valve. The valve is

composed of the main valve, main valve seat, a pressure adjusting air chamber, and the

main diaphragm, pilot diaphragm, and pilot valve for pressure sensing and activation.

No.

Parts name

Body

Main Valve

Main Valve Seat

Main Diaphragm

Main Valve Spring

Screen

Pilot Valve

Pilot Valve Seat

Pilot Diaphragm

23-2

Air pressure sensing port

Tee

34,35,36

Pipe A,B,C

12-1

Main diaphragm chamber

23-1

Pilot diaphragm chamber

56-1

Reduced pressure sensing

port

(1) When the pressure reducing valve is mounted correctly, the main valve [6] and pilot valve

[17] should be closed by main valve spring [13] and pilot valve spring [19] when air pressure

is no-pressure. Slowly open the gate valve and allow the high-pressure fluid to flow in. Inlet

pressure is applied to the upside of the main valve. High pressure fluid passes through

screen [15] to also apply inlet pressure to the downside of the pilot valve. (Fig. 1)

■EPDT-098a■

-5-

Fig.2

Fig.3

(2) Introducing air pressure into air chamber flexes pilot diaphragm [23] to open the pilot valve.

The fluid passing through pilot valve [17] and pilot valve seat [18] enters the main diaphragm

chamber [12-1] via pipes [34] and [36]. This fluid also flows to the reduced side of the body

[1] through the orifice of tee [33] and pipe [35] that connects to the body. (Fig. 2)

(3) When the flow rate at the pilot valve exceeds the flow rate at the orifice, operating pressure

in the main diaphragm chamber raised and overrides the pressure on the upside 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. (Fig. 3)

■EPDT-098a■

-6-

Fig.4

(4) Reduced pressure is led to the pilot diaphragm chamber [56-1] via the sensing pipe and

reduced pressure sensing port [23-1]. The pilot diaphragm receives the reduced pressure to

be balanced with the air pressure. The pilot valve travel is controlled by the air pressure and

pressure applied to the pilot diaphragm due to variations in reduced pressure. This changes

the flow rate of fluid to the main diaphragm chamber, which controls the main valve travel to

obtain appropriate reduced pressure. (Fig. 4)

■EPDT-098a■

-7-

4. Nominal Size Selection Method

4.1 Pressure reducing valve specification selection chart

Refer to the above selection chart to select the most appropriate pressure reducing valve.

Find the point of intersection of inlet pressure(P1) and reduced pressure(P2). When the point

of intersection is within range(A), reduce pressure in two stages. When within range (C),

maximum performance cannot be obtained. When reducing pressure in two stages,

maximize the distance between the valves (at least 3 m).

4.2 Safety valve setting pressure chart

This chart is for setting the safety valve (for alarms) used for steam pressure reducing

valves.

Determine the reduced pressure of pressure reducing valve. Find the intersection point (A)

with the chart curve. Next, find point (B) by proceeds horizontally from point (A) to the left

until the ‘Setting pressure of safety valve’ axis. The setting pressure of the safety valve

should be higher than the pressure of the point (B).

■EPDT-098a■

-8-

4.3 Characteristic chart

(1) Flow rate characteristics chart

● Shut-off pressure rise: 0.02 MPa or less

● Offset: 10% or less of set pressure at outlet side (Minimum value: 0.0MPa)

Using the nominal size selection chart, select the nominal size of 80 ~ 90% of the flow rate,

considering pressure loss and heat loss of the gate valve and the strainer before and after

the pressure reducing valve. To fully utilize the flow characteristics of the valve, do not select

a small pipe size, considering the effects due to pipe resistance.

(2) Pressure characteristics chart

Reduced pressure is set to 0.14 MPa when inlet pressure is 1.75 MPa. The chart indicates

a variation in reduced pressure when the inlet pressure is changed within the range of 0.2

to 2.0 MPa.

■EPDT-098a■

-9-

4.4 Nominal size selection chart (External sensing)

* Please contact us on internal sensing method.

For example, take a pressure reducing valve whose inlet pressure (P1) is 0.6 MPa, reduced

pressure (P2) 0.4 MPa, flow rate 600 kg/h. When determining the nominal size, 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 600 kg/h, and regard this point as (B).

Point (B) is between nominal sizes 20A and 25A. Select the larger nominal size (in this

example, nominal size 25A)

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