Yoshitake GP-1000 Manual de usuario

■EPDT-081a■

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.

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





Warning





Caution

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

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-081a■

-1-

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

Model GP-1000 GP-1010GP-1000SS GP-1000H GP-1002 GP-1012

Connection Flanged

(JIS 10K FF) JIS Rc Screw Flanged

(JIS 10K FF) Flanged

(JIS 16K FF) Flanged

(JIS 10K FF) JIS Rc Screw

Nominal size 15～100A 15～50A 15～100A 15～100A 15～100A 15～50A

Application Steam

Inlet pressure 0.1～1.0 MPa 0.1～1.6 MPa 0.1～0.5 MPa

0.05～0.9 MPa

0.9～1.4 MPa

0.03～0.15 MPa

Reduced pressure

90% or less of inlet pressure (gauge pressure)

Min. differential

pressure 0.05 MPa

Max. pressure

reducing ratio 20：1

Max. temperature 220℃

Valve seat leakage 0.01% or less of rated flow

Body Ductile cast iron Stainless steel Ductile cast iron

Valve Stainless steel

Valve seat Stainless steel

Piston/Cylinder Brass or Bronze Stainless steel Brass or Bronze

Material

Gasket Non asbestos

Body hydraulic test 2.0 MPa 3.2 MPa 1.0 MPa

lStainless steel main components (piston & cylinder) are also available.(GP-1□□□S)

lAll stainless steel types are also available for GP-1000.

lAdjusting handle types are also available for GP-1000 and GP-1010.(GP-1001,1011)





Caution

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

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

■EPDT-081a■

-2-

3. Dimensions and Weights

•GP‑1000,1000H,1002

(㎜)

Size ＬＨＨ

１Weight（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 ＬＨＨ

１Weight（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

■EPDT-081a■

-3-

4. Operation

No. Parts name

1 Body

5 Diaphragm

8 Adjusting spring

9 Adjusting screw

11 Main valve

12 Main valve seat

13 Main valve spring

14 Piston

15 Cylinder

19 Pilot valve

20 Pilot valve seat

28 Strainer

42 Inlet press. passage

43 Reduced press. Sensing port

44 Diaphragm chamber

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.

■EPDT-081a■

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5. Nominal Size Selection Method

5.1 Pressure reducing valve specification selection chart

Find the intersection point of the inlet

and reduced pressures. The GP-1000

series valves are suitable within range

(A), (B), (C), and (D).

・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）

5.2 Safety valve setting pressure

Reduced pressures (MPa) Safety valve setting pressure (MPa)

0.03～0.1 Reduced pressures＋more than 0.05

0.1～0.4 Reduced pressures＋more than 0.08

0.4～0.6 Reduced pressures＋more than 0.1

0.6～0.8 Reduced pressures＋more than 0.12

0.8～1.4 Reduced pressures＋15％

5.3 Characteristics chart

(1) Flow rate characteristics chart

•Shut-off pressure raise : 0.02 MPa or less

•Offset : 0.03 MPa or less

(Setting pressure: 0.03~0.1 MPa)

: 0.05 MPa or less

(Setting pressure: 0.1~1.4 MPa)

(2) Pressure characteristics chart

Reduced pressure is set to 0.1 MPa

when inlet pressure is 1.0 MPa. The

chart indicates a variation in reduced

pressure when the inlet pressure is

changed from 1.6 to 0.3 MPa.

10050

Offset

Shut‑offpressureraise

5Flowrate

Setting

pressure

(%)0

Reduced

pressure

Min.adjustableflowrate Ratedflow

■EPDT-081a■

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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.

■EPDT-081a■

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：Inletpressure　MPa

1.0

0.7

0.8

0.9

1.6

1.4

1.2

1.1

1.3

1.5

(ロ)(イ)

0.4

0.5

0.6

0.7

0.8

0.9

1.0

0.00 0.05 0.100.15 0.20 0.25 0.30 0.35 0.40

：Re duced pr essure MPa

C ：Correction coefficient

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

•Rated Cv value table (When Cv correction coefficient is C=1)

Nominal size 15A 20A 25A 32A 40A 50A 65A 80A 100A

Rated Cv value 1 2.3 4 6.5 9 16 25 36 64

※Correction of rated Cv value

If the inlet pressure exceeds 0.7 MPa, and the pressure reducing is 0.4 MPa or less,

find the appropriate correction coefficient C using chart below, and multiply the rated

Cv value, and obtain the corrected Cv value.

[Ex.]

Take a pressure reducing valve whose inlet

pressure is 0.8 MPa, reduced pressure is 0.05

MPa. Find the inlet and reduced pressure

intersection point (A) at the left chart, then

draw a horizontal line in the leftward

direction to point (B) which indicates a

correction coefficient of 0.85. For a nominal

size of 25A, the corrected Cv value would be

calculated as follows:

4(rated Cv value) ×0.85(correction

coefficient) = 3.4

6. Installation

6.1 Example of piping

W: Max. steam flow rate [kg/h]

P1: Inlet pressure [MPa･A]

P2: Reduced pressure [MPa･A]

ΔP: P1−P2 [MPa]

k: 1+0.0013 ×{super-heated steam

temp.[℃]−saturated steam

temp.[℃]}

)PP(P138

Cv 21 +∆

1120P

Cv =

■EPDT-081a■

-7-

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)

Fig.1

Nominal

size AB

15A

20A 125

25A 315 135

32A

40A 335 155

50A 345 175

65A 355 190

80A 375 225

100A 395 265

■EPDT-081a■

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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.

7.2 Adjustment procedures

Follow the steps below, and slowly turn the adjusting screw to set pressure. Incorrect adjustment may

cause hunting, water hammer, etc., resulting in damage to the valve and other equipment.

（1）Close the stop valve at inlet and outlet side of the pressure reducing valve, and taking sufficient

time not to blow the safety valve, blow off the fluid to remove foreign matter via the by-pass line.

After blowing, close the by-pass line stop valve.

（2）Slowly open the stop valve at the inlet side of the pressure reducing valve, and adjust the travel of

the stop valve at the outlet side of the pressure reducing valve so that a little fluid flows.

（3）Loosen the lock nut, and slowly turn the adjusting screw to achieve the desired pressure

(clockwise to increase, counterclockwise to reduce) while observing the pressure gauge on the

outlet side. While adjusting the pressure, push down and turn the handle slowly because the handle

is locked in normal position and look at the secondary side of pressure gauge closely. (Secondary

pressure rises by turning the handle in clockwise and descends in counterclockwise).

（4）Slowly open the stop valve at the outlet of the pressure reducing valve, and readjust the desired

pressure.

（5）After adjustment, tighten the lock nut. For the model with handle, handle is pulled up and locked

by releasing hold. If it is not locked, turn the handle to left and right then release it.

■EPDT-081a■

-9-

8. Maintenance Procedure

8.1 Troubleshooting

Problem Cause Solution

Pressure does not

reach the desired

value.

1．Incorrect pressure is being used.

2．Strainer [28] is clogged.

3．Foreign matter exists between

piston [14] and cylinder [15].

4．Piston ring [16] is damaged.

5．Nominal size is too small for the

specifications.

6．Pressure is not adjusted correctly.

7．Strainer installed before pressure

reducing valve is clogged.

8．Pressure gauge is faulty.

1．Correct the pressure.

2．Disassemble and clean the strainer.

3．Disassemble and remove the foreign

matter. When any scratches are

identified, polish them away using a

paper. Change the parts if scratches

still exist after polishing.

4．Replace the piston ring.

5．Change the nominal size appro-

priately.

6．Observe the adjustment procedures

and readjust pressure.

7．Disassemble and clean it.

8．Replace it.

Reduced pressure

raises above than

the specified value.

1．Foreign matter exists between main

valve [11] and main valve seat

[12], or scratches exist.

2．Foreign matter exists between pilot

valve [19] and pilot valve seat [20],

or scratches exist.

3．Foreign matter exists between piston

[14] and cylinder [15].

4．Trap is not provided for dead-end

line.

5．By-pass valve is leaking.

6．Diaphragm [5] is damaged.

1．Disassemble and remove the foreign

matter. When any scratches are

identified, lap the main valve and

main valve seat. Change the parts if

scratches still exist after lapping.

2．Disassemble the pilot valve as-

sembly, and clean or replace it.

3．Disassemble and remove the foreign

matter. When any scratches are

identified, polish them away using a

paper. Change the parts if scratches

still exist after polishing.

4．Install a trap.

5．Repair or replace it.

6．Replace the diaphragm.

Abnormal noise is

heard.

1．Nominal size is too large for the

specifications.

2．Pressure reducing ratio is too large.

3．Drainage problem is caused.

4．An abrupt OPEN/CLOSE valve is

located too close to the pressure

reducing valve.

5．Outlet pipe is too small.

1．Change the nominal size appro-

priately.

2．Reduce pressure in two stages.

3．Install a trap.

4．Allow as much as possible between

the valves.

5．Select a pipe size that will produce a

flow velocity of 30m/s or less.

lForeign matter and scales in a pipe may cause most of problems of pressure reducing valve. Be

careful sufficiently to foreign matter in a pipe.

lPhenomenon alike valve trouble may happen by fault of pressure gauge, fluid leakage from by-

pass valve, forgetting to close the by-pass valve, clogging strainer, and etc. First, check the said

particulars before above troubleshooting.

lConsult factory when cannot make a judgement whether parts need replacement or not.

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