The TLV COSR-3 and COSR-16 are self-actuated pressure reducing valves with a shock-absorbing piston, designed for accurate control in process steam systems. Steam-using equipment can perform its intended operation only when dry saturated steam is available. The COSR series helps eliminate problems caused by entrained condensate by supplying dry saturated steam at a constant pressure at all times.

Features

Technologically advanced, pilot operated pressure reducing valve for accurate control in process steam systems.

1. Self-aligning shock-absorbing spherical piston and advanced pilot regulator designs maintain secondary steam pressure accuracy, even during adverse process conditions.
2. Major internal components made of stainless steel for long service life.
3. Large surface area integral screen for pilot valve extends trouble-free service.
4. Internal secondary pressure-sensing channel makes external sensing line unnecessary.
5. Sizes DN 65 and larger have a silencer for noise reduction.

Specifications

WARNING

To avoid malfunctions, product damage, accidents or serious injury, install properly and DO NOT use this product outside the specification range. Local regulations may restrict the use of this product to below the conditions quoted.

Acceptable Operating Range

Model	COSR-3	COSR-16
Primary Pressure Range (barg)	1 to 3	2 to 16
Secondary Pressure Adjustable Range	0.1 to 0.5 barg (Minimum 0.3 barg)	Within 10 to 84% of primary pressure (Minimum 0.55 barg)
Pressure Differential	0.7 to 8.5 barg	Maximum 8.5 bar
Minimum Adjustable Flow Rate	5% of rated flow rate	5% of rated flow rate; 10% for sizes 65 mm and larger

Specifications

Model	COSR-3	COSR-16
Body Material	Cast Iron, Ductile Cast Iron, Cast Stainless Steel	Cast Iron, Ductile Cast Iron, Cast Stainless Steel
Connection	Screwed, Flanged	Screwed, Flanged
Size	1/2" to 1", DN 20 to 50	1/2" to 1", DN 15 to 150
Max. Operating Pressure (PMO)	3 barg	16 barg (13 barg for Cast Iron)
Max. Operating Temperature (TMO)	200 °C / 220 °C	200 °C / 220 °C

Configuration

No.	Description	Material
1	Main Body	Ductile Cast Iron / Cast Stainless Steel / Cast Iron
2	Cover Plug / Cover	Same material as main body
3	Main Valve Seat	Stainless Steel
4	Main Valve	Stainless Steel
5	Main Valve Holder	Stainless Steel
6	Piston	Stainless Steel
7	Cylinder	Stainless Steel
8	Pilot Body	Same material as main body

Capacity Tables

COSR-3 Capacity (kg/h)

Primary Steam Pressure (barg)	Secondary Steam Pressure (barg)	DN 20	DN 25	DN 32	DN 40	DN 50
1 to less than 2	0.5	120	180	540	750	950
	0.4	130	190	520	700	920
	0.3	135	195	510	680	900
2 to 3	0.5	240	340	540	750	950
	0.4	230	330	520	700	920
	0.3	240	340	510	680	900

Cv & Kvs Values

	DN 15	DN 20	DN 25	DN 32	DN 40	DN 50	DN 65	DN 80	DN 100	DN 150
Kvs (DIN)	3.3	5.9	9.5	13.3	20.6	31.9	50.8	72.9	110	236
Cv (US)	3.8	6.9	11.1	15.5	24.0	37.2	59.3	85.0	128	275

INFO

The Cv & Kvs values shown are for the valve in the full open position. These values are not to be used for COSR sizing, and instead may be used as one of the factors in calculations for safety valve selection.

Dimensions

Screwed

Size	L (mm)	H (mm)	H1 (mm)	Weight (kg)
1/2", 3/4"	175	357	285	8.2
1"	190	357	282	8.4

Flanged

DN	L (DIN 2501) (mm)	H (mm)	H1 (mm)	Weight (kg)
15	130	357	285	8.8
20	150	357	285	9.5
25	160	357	282	11
32	180	385	302	16
40	200	385	302	17
50	230	412	315	26

Piping and Installation

WARNING

Installation, inspection, maintenance, repairs, disassembly, adjustment and valve opening/closing should be carried out only by trained maintenance personnel. Install for use under conditions in which no freeze-up will occur and no water hammer will occur.

Recommended Straight Pipe Runs

If the COSR is installed either directly before or after an elbow or control valve, unevenness in flow may result in chattering and unstable pressure. To ensure stable steam flow, it is recommended that the COSR be installed on straight runs of piping.

• Inlet: Maintain a straight piping run of 10d or more when a manual valve, strainer or elbow is installed. Maintain 30d or more when an automated valve (on-off valve) is installed.
• Outlet: Maintain a straight piping run of 15d or more when a manual valve, strainer or elbow is installed. Maintain 30d or more when a safety valve, another pressure reducing valve, or a control valve is installed.

Installing a Control Valve

A control valve (i.e. for temperature control) installed between the COSR and the steam equipment may raise pressure between the COSR and the control valve when closed. The control valve should be installed close to the steam-using equipment, and a safety valve should be installed downstream of the control valve.

Strainer Installation

A strainer should be installed ahead of the COSR. The strainer should be 60 mesh or finer, installed horizontally and at 90° to its normal orientation to the pipeline, in order to prevent condensate accumulation in the screen body.

Adjustment

1. It is necessary to blow down all pipe lines thoroughly.
2. Make sure that the shutoff valve and the bypass valve located upstream and downstream of the COSR are completely closed.
3. Remove the spanner cap, loosen the locknut and turn the adjustment screw counterclockwise to reduce tension on the coil spring.
4. Slowly, fully open the shutoff valve at the inlet of the COSR.
5. Slightly open the shutoff valve at the outlet of the COSR.
6. Turn the adjustment screw until the desired outlet pressure is obtained (turn clockwise to increase pressure). Wait several minutes.
7. Slowly, fully open the shutoff valve on the outlet side.
8. After setup, tighten the locknut and replace the spanner cap.