Universal Excess Pressure Valve Type 41-73

Fig. 1 Type 41-73 Universal Excess Pressure Valve

Mounting and Operating Instructions EB 2517 EN

Edition September 2003

Contents

Contents 1. 2. 2.1 2.2 2.3 2.4 2.5 2.6 3. 3.1 3.2 4. 4.1 5. 6. 7. Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . Mounting position . . . . . . . . . . . . . . . . . . . . . . . . Control line, condensation chamber and screw joint with restriction Strainer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Shut-off valve . . . . . . . . . . . . . . . . . . . . . . . . . . Pressure gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Page Design and principle of operation . . . . . . . . . . . . . . . . . . . . . . 4 . . . . . . . 6 6 6 7 8 8 8

Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Set point adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Maintenance Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . 9 Replacing the operating diaphragm . . . . . . . . . . . . . . . . . . . . . 9 Description of nameplates . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Dimensions in mm and weights . . . . . . . . . . . . . . . . . . . . . . . 12 Customer inquiries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

EB 2517 EN

Safety instructions

General safety instructions

 The pressure regulator may only be mounted, started up or serviced by fully  The pressure regulator fulfils the requirements of the European Pressure Equip trained and qualified personnel, observing the accepted industry codes and practices. Make sure employees or third persons are not exposed to any danger.

 Proper shipping and appropriate storage are assumed.

Caution!

ment Directive 97/23/EC. Valves with a CE marking have a declaration of conformity which includes information about the applied conformity assess ment procedure. The declaration can be viewed and downloaded on the Inter net at http://www.samson.de. For appropriate operation, make sure that the regulator is only used in areas where the operating pressure and temperatures do not exceed the operating values which are based on the valve sizing data submitted in the order. The manufacturer does not assume any responsibility for damage caused by external forces or any other external influence! Any hazards which could be caused in the pressure regulator by the process medium, the operating pressure or by moving parts are to be prevented by means of the appropriate measures.

 Self-operated regulators must not be put into operation before all compo  When removing the self-operated regulator from the pipeline, make sure the  Allow the plant to fill slowly on start-up.
nents, e.g. valve, actuator and control lines, have been mounted. Open all control lines and check that they are correctly connected prior to start-up.

sections of the pipeline that the control lines are connected to are also depress urized. If this is not possible, shut off the control lines. On pressurizing the plant to carry out a pressure test, make sure the dia phragm actuator is not damaged by the test pressure. The maximum permissible pressure in the actuator must not be exceeded. Dis connect all external control lines.

 Make sure the regulators are frost protected when they are used to control

freezing process media, e.g. water. If the regulator is installed in locations sub ject to frost, the regulator must be removed from the pipeline when it is not operated.

EB 2517 EN

Design and principle of operation

1. Design and principle of operation

The Type 41-73 Excess Pressure Valve consists of a Type 2417 Opening Valve and a Type 2413 Actuator. The valve and actuator are delivered as separate items and must be assembled according to the instructions in section 2.1. The excess pressure valve is used to maintain the pressure upstream of the valve at an adjusted set point. The process medium to be regulated flows through the valve between the seat (2) and the plug (3) in the direction indicated by the arrow on the body. The position of the valve plug determines the flow rate, and thus the pressure ratio at the valve. The plug stem is sealed by a frictionless metal bellows (5.1). The upstream pressure p1 is transmitted through the condensation chamber (18) and the control line (17) to the operating diaphragm (12) and is converted into a positioning force. For actuator versions with bellows, the pressure is transmitted to the operating bellows (12.1). The positioning force is used to move the valve plug according to the force of the positioning springs (7). The spring force is adjustable at the set point adjustment (6). The control valves with a Kvs value of 2.5 or higher feature a balancing bellows (4). The upstream pressure acts on the outer bellows surface, the downstream pressure on the inner bellows surface. As a result, the forces produced by the upstream and downstream pressures acting on the plug are balanced.

Depending on the valve and actuator used, the regulator can be extended to form a millibar excess pressure valve or a safety excess pressure valve.

1 2 3 4 5 5.1 6 7 8 9 10 11 12 12.1 13 14 15 16 17

18 19

Valve body Seat Plug Balancing bellows Plug stem Bellows seal Set point adjustment Positioning springs Bracket Fastening nuts Actuator Actuator stem Operating diaphragm Operating bellows Diaphragm plate Nut Nuts and bolts Control line connection (with screw joint with restriction for steam) Control line to be provided by the operator (control line kit also available as accessory for connection directly at the valve body) Condensation chamber Filler neck

EB 2517 EN

Design and principle of operation

18

19

1 3 2

5 6 4 16 12.1 5.1 7
Pillar turned 90 into plane of projection

9
Actuator with operating bellows (12.1) for 5 to 10, 20 to 28 and 10 to 22 bar

17 15

8 11 12 10 13 14

16

DN 65 to 100

Fig. 2 Sectional drawings

EB 2517 EN

Installation

2. Installation 2.1 Assembly

Valve and actuator can be assembled before or after the control valve has been installed in the pipeline. Push the actuator (10) with the actuator stem (11) through the hole in the bracket (8) onto the spigot of the bellows seal (5.1). Align and secure it with the nuts (9, width across flats SW 17). For actuators with metal bellows in sizes DN 65 to 100, remove the bracket (8) from the valve and unscrew the pillar. Screw the pillar into the actuator flange. Push the actuator onto the valve and secure the pillar at the valve flange using nuts.

If the pipeline upstream and downstream of the valve is routed vertically upwards, an automatic water drainage (SAMSON Type 13E Steam Trap) is required. Make sure you choose a place of installation that allows you to freely access the regulator even after the entire plant has been completed. The regulator must be installed free of stress. If necessary, support the piping near the connections. Caution! Never attach supports directly to the valve or actuator. Do not install any devices (e.g. temperature regulators or shut-off valves) which restrict the cross-section of the pipe between the pressure tapping point and the control valve. If a bypass line is to be used, it must be connected upstream of the pressure tapping point. Install a shut-off valve in the bypass line.

2.2 Mounting position

Caution! Flush the pipeline thoroughly before installing the regulator to ensure that any sealing parts, weld spatter and other impurities carried along by the process medium do not impair the proper functioning of the valve, above all the tight shut-off. A strainer (SAMSON Type 2) must be installed upstream of the regulator (see section 2.4). Install the pressure reducing valve in a horizontal pipeline. On installing the valve, make sure the direction of flow corresponds with the arrow on the body. For media with a tendency to condensate, install the pipeline with a slight downward slope on both sides so that the condensate can drain properly.

Standard mounting position for medium temperatures above 0 C. Not permissible for millibar excess pressure valves! Optional mounting position for gases and liquids up to medium temperatures of 80 C. Mandatory mounting position for millibar excess pressure valves.

Not permissible.

EB 2517 EN

Installation

2.3 Control line, condensation chamber and screw joint with restriction
A control line must be provided in the form of a 3/8" pipe for steam and an 8 x 1 or 6 x 1 mm pipe for air/water. Control line kit: A kit for tapping pressure directly at the valve body is available as an accessory. Condensation chamber: A condensation chamber is required for liquids above 150 C as well as for steam. The mounting position of the condensation chamber is indicated by an adhesive label on the chamber itself as well as by an arrow and the word "top" stamped onto the top of the chamber. This mounting position must be adhered to; otherwise the safe functioning of the excess pressure valve cannot be guaranteed.

Weld the line coming from the pressure tapping point to the 3/8" filler neck on the condensation chamber. The condensation chamber must always be installed at the highest point of the pipeline. Consequently, the control line between condensation chamber and actuator must also be installed with a downward slope. In this case, use a 3/8" pipe with screw gland. Connect the control line to the upstream line (p1) at least one meter away from the valve outlet (Fig. 3). Note! If the regulator tends to hunt, we recommend to mount a SAMSON screw joint with restriction on the control line connection (16).

Caution! Millibar excess pressure valves must be installed vertically with the actuator on top. Fig. 3 Installation example

1 2 3 4 5 6 7

Shut-off valve Upstream pressure gauge Strainer Condensation chamber Excess pressure valve Downstream pressure gauge Shut-off valve

EB 2517 EN

Operation

2.4 Strainer
The strainer must be installed upstream of the excess pressure valve. Make sure the direction of medium flow corresponds with the direction indicated by the arrow on the strainer. The filter element must be vertically suspended. Remember to leave enough space to remove it.

3. Operation 3.1 Start-up

Caution! For millibar excess pressure valves (1200 cm2 actuator), the max. permissible differential pressure is 10 bar. The max. per missible pressure at the actuator must not ex ceed 0.5 bar. For regulating steam: Unscrew filler neck (19) on the condensation chamber. Using either the included plastic funnel or a jug, pour in water until it starts to overflow. Screw the filler neck back in and tighten it. The excess pressure valve is now ready for operation. Open the hand-operated shut-off valves slowly to prevent water hammer. For regulating liquids: To start up the excess pressure valve, open shut-off valves slowly. For actuators with an effective diaphragm area of 640 cm2, loosen the vent screw. Allow all the air to escape, then retighten it. For temperatures above 150 C, the necessary condensation chamber must first be filled with the process medium.

2.5 Shut-off valve

We recommend to install a hand-operated shut-off valve both upstream of the strainer and downstream of the regulator to be able to shut down the plant for cleaning and maintenance, and when the plant is not used for longer periods of time.

2.6 Pressure gauge

To monitor the pressures in the plant, install a pressure gauge both upstream and downstream of the regulator. Note that the pressure gauge on the upstream side should not be installed upstream of the pressure tapping point.

3.2 Set point adjustment

The required upstream pressure (excess pressure) is set by turning the set point adjustment (6) using an open-end wrench up to DN 50 with width across flats SW 19 and for DN 65 and larger with SW 22.

EB 2517 EN

Maintenance Troubleshooting

Turning clockwise increases the upstream pressure, turning counterclockwise reduces it. The pressure gauge located on the upstream pressure side allows the adjusted set point to be monitored.

4. Maintenance Troubleshooting
The excess pressure valve is maintenance free. Nevertheless, it is subject to natural wear, particularly at the seat, plug and operating diaphragm. Depending on the operating conditions, the regulator needs to be checked at regular intervals to avoid possible malfunctions. Details on faults and how to correct them can be found in the table on page 10. If a problem cannot be solved with the help of the information specified in the table, contact SAMSON. Note! If a repair is performed by the plant operator, make absolutely sure that no torque is applied to the bellows seal (5.1) during assembly or disassembly. Otherwise, the metal bellows would be destroyed. Caution! When working on the pressure regulator, make sure the relevant section of the pipeline is depressurized and, depending on the process medium, drained as well. For high temperatures, allow the regulator to cool down to ambient temperature before starting any work on it. The control line must be interrupted or shut off to avoid any hazards which could be caused by moving

parts of the regulator. As valves are not free of cavities, remember that residual process medium might still be contained in the valve. This applies in particular to valve versions with a balancing bellows. It is recommended to remove the valve from the pipeline.

4.1 Replacing the operating diaphragm

If the excess pressure deviates from the set point considerably, check if the diaphragm is leaking and, if necessary, replace it. 1. Shut down the plant by slowly closing the shut-off valves. Relieve the relevant section of the pipeline of pressure and, if necessary, drain it as well. 2. Unscrew the control line (17) and clean it. 3. Loosen the bolts (15) at the actuator and remove the cover plate. 4. Unscrew the nut (14) and lift off the diaphragm plate (13). 5. Replace the operating diaphragm (12) with a new one. 6. Proceed in the reverse order to reassemble the regulator. For start-up, proceed as described in section 3.1.

EB 2517 EN

Maintenance Troubleshooting

Fault Pressure exceeds the adjusted set point

Possible reasons Pressure impulse on the actuator diaphragm not sufficient Seat and plug worn out by deposits or foreign particles Pressure tapped in wrong location When used to regulate steam: Condensate chamber improperly positioned or chamber too small Control response too slow

Solution Clean the control line and screw joint with restriction Disassemble the regulator and exchange the damaged parts Rebuild the control lines, do not tap at pipe bends or necks Reinstall or exchange the condensation chamber, required size for 160 cm2 actuators: 0.7 l, for 320 cm2 and larger: 1.7 l Install larger screw joint with restriction at the diaphragm actuator Disassemble the regulator and exchange the damaged parts Check direction of flow, reinstall the valve Rebuild the control line Reinstall the condensation chamber, see Fig. 3 for mounting position Exchange the damaged parts

Pressure drops below the adjusted set point

Foreign particle blocks the plug Valve installed against direction of flow, see arrow on the body Pressure tapped in wrong location When used to regulate steam: Condensation chamber improperly positioned

Jolting control response Slow control response Upstream pressure hunts

Increased friction, e.g. due to foreign particles between the seat and plug Restriction in the actuator screw joint too small Dirt in the control line Valve too large Restriction in the actuator screw joint too large Inappropriate pressure tapping point

Install larger screw joint with restriction Clean the control line Check sizing, choose smaller KVS value if necessary Install smaller screw joint with restriction Choose appropriate pressure tapping point

10

EB 2517 EN

Description of nameplates

High noise emission

High flow velocity, cavitation

Check sizing, install a flow divider when used to regulate steam and gases

5. Description of nameplates
Valve nameplates
2
SAMSON
bar DN PN p

1
No bar T

4
Kvs C

Made in Germany

DIN version

10

11

12

1 2 3 4 5 8 9 10 11 12

Valve type Model number Model number index Order number or date K85 value Nominal size Nominal pressure Perm. differential pressure Perm. temperature Body material

2
SAMSON
psi N p

3
psi T F

1
No Cv

4
Size Cl

Made in Germany

With ANSI version 5 Size 8 Perm. differential pressure 9 Perm. temperature (F) 10 Body material 11 C8 value (K85 x 1.17) 12 ANSI Class (pressure rating)

ANSI version

10

11

12

Actuator nameplate
1
SAMSON
DIN ANSI Type PN pmax No psi Size bar DN

2
psi bar

3
A

4
sq.in cm 2 psi bar
2002 0062

12

Made in Germany

7 8

10

11

1 2 3 4 5 6 7 8 9 10 11 12

Model number Model number index Order number or date Effective area Labeling acc. to DIN Labeling acc. to ANSI Maximum perm. pressure Nominal size Differential pressure Set point range Diaphragm material Year of manufacture

Fig. 4 Nameplates

EB 2517 EN

11

Dimensions in mm and weights

6. Dimensions in mm and weights

DN Set point range bar L1 Length L PN 16 PN 40 Height H1 Height H3 0.005...0.03 Height H Actuator 0.025...0.05 Height H Actuator 0.05...0.25 Height H Actuator 0.1...0.6 Height H Actuator 0.2...1.2 Height H Actuator 0.8...2.5 Height H Actuator 2...5 Height H Actuator 4.5...10 Height H Actuator 8...16 Height H Actuator 0.005...0.05 0.05...0.6 0.2...2.5 2...16


15 130 220

20 150 256 335 55

25 160 278

32 180 314

40 200 337 390 72

50 230 380

65 290 464 471 510 100

80 310 510

100 350 556 570 525 120

435 D = 490 mm 435 D = 490 mm 445 D = 380 mm 445 D = 380 mm 430 D = 285 mm 430 D = 225 mm 410 465 D = 170 mm 410 465 D = 170 mm 410 465 D = 170 mm 28.5 22.5 16 12 29.5 23.5 18 13 33.5 29.5 23.5 18.5 37.5 31.5 25.5 21 A = 40 cm 41 35 29 24 57 51 45 40 64 58 52 47 67 61 56 A = 40 cm 585 600 A = 80 cm 585 600 485 A = 160 cm 585 600 480 A = 320 cm 605 620 500 A = 640 cm 600 620 500 A = 640 cm 620 635 A = 1200 cm 490 A = 1200 cm 620 635 610

Weight for cast iron PN 16  Approx. kg

+10 % for cast steel PN 40 and spheroidal graphite iron PN 25

12

EB 2517 EN

Dimensions in mm and weights

L1 L

H3

Conical expansion piece

H1 H max. 215

25

EB 2517 EN

13

Customer inquiries

7. Customer inquiries
If you have any questions regarding the excess pressure valve, please submit the following details (also see nameplate): Regulator type and nominal size Product and order number as specified on the nameplate Pressure upstream and downstream of the valve Flow rate in m3/h Has a strainer been installed? Installation drawing

     

14

EB 2517 EN

EB 2517 EN

15

SAMSON AG MESS- UND REGELTECHNIK Weismllerstrae 3 60314 Frankfurt am Main Germany Phone: +49 69 4009-0 Fax: +49 69 4009-1507 Internet: http://www.samson.de

EB 2517 EN

S/Z 2003-10

Universal Pressure Reducing Valve Type 41-23

Fig. 1 Type 41-23 Universal Pressure Reducing Valve

Mounting and Operating Instructions EB 2512 EN

Edition September 2003

Contents

Contents 1. 2. 2.1 2.2 2.3 2.4 2.5 2.6 3. 3.1 3.2 4. 4.1 5. 6. 7. Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . Mounting position . . . . . . . . . . . . . . . . . . . . . . . . Control line, condensation chamber and screw joint with restriction Strainer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Shut-off valve . . . . . . . . . . . . . . . . . . . . . . . . . . Pressure gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Page Design and principle of operation . . . . . . . . . . . . . . . . . . . . . . 4 . . . . . . . 6 6 6 7 8 8 8

Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Set point adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Maintenance Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . 9 Replacing the operating diaphragm . . . . . . . . . . . . . . . . . . . . . 10 Description of nameplates . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Dimensions in mm and weights . . . . . . . . . . . . . . . . . . . . . . . 14 Customer inquiries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

EB 2512 EN

Safety instructions

General safety instructions

 The pressure regulator may only be mounted, started up or serviced by fully  The pressure regulator fulfils the requirements of the European Pressure Equip trained and qualified personnel, observing the accepted industry codes and practices. Make sure employees or third persons are not exposed to any danger.

 Proper shipping and appropriate storage are assumed.

Caution!

ment Directive 97/23/EC. Valves with a CE marking have a declaration of conformity which includes information about the applied conformity assess ment procedure. The declaration can be viewed and downloaded on the Inter net at http://www.samson.de. For appropriate operation, make sure that the regulator is only used in areas where the operating pressure and temperatures do not exceed the operating values which are based on the valve sizing data submitted in the order. The manufacturer does not assume any responsibility for damage caused by external forces or any other external influence! Any hazards which could be caused in the pressure regulator by the process medium, the operating pressure or by moving parts are to be prevented by means of the appropriate measures.

 Self-operated regulators must not be put into operation before all compo  When removing the self-operated regulator from the pipeline, make sure the  Allow the plant to fill up slowly on start-up.
nents, e.g. valve, actuator and control lines, have been mounted. Open all control lines and check that they are correctly connected prior to start-up.

sections of the pipeline that the control lines are connected to are also depress urized. If this is not possible, shut off the control lines. On pressurizing the plant to carry out a pressure test, make sure the dia phragm actuator is not damaged by the test pressure. The maximum permissible pressure in the actuator must not be exceeded. Dis connect all external control lines. freezing process media, e.g. water. If the regulator is installed in locations sub ject to frost, the regulator must be removed from the pipeline when it is not operated.

 Make sure the regulators are frost protected when they are used to control

EB 2512 EN

Design and principle of operation

1. Design and principle of operation

The Type 41-23 Pressure Reducing Valve consists of a Type 2412 Closing Valve and a Type 2413 Actuator. The valve and actuator are delivered as separate items and must be assembled according to the instructions in section 2.1. The pressure reducing valve is used to maintain the pressure downstream of the valve at an adjusted set point. The process medium to be regulated flows through the valve between the seat (2) and the plug (3) in the direction indicated by the arrow on the body. The position of the valve plug determines the flow rate, and thus the pressure ratio at the valve. The plug stem is sealed by a frictionless metal bellows (5.1). The downstream pressure p2 is transmitted through the condensation chamber (18) and the control line (17) to the operating diaphragm (12) and is converted into a positioning force. For actuator versions with bellows, the pressure is transmitted to the operating bellows (12.1). The positioning force is used to move the valve plug according to the force of the positioning springs (7). The spring force is adjustable at the set point adjustment (6). The control valves with a Kvs value of 2.5 or higher feature a balancing bellows (4). The upstream pressure acts on the outer bellows surface, the downstream pressure on the inner bellows surface. As a result, the forces produced by the upstream and downstream pressures acting on the plug are balanced.

Depending on the valve and actuator used, the regulator can be extended to form a millibar pressure reducing valve, steam pressure reducing valve or a safety pressure reducing valve.

1 2 3 4 5 5.1 6 7 8 9 10 11 12 12.1 13 14 15 16 17

18 19 20

Valve body Seat Plug Balancing bellows Plug stem Bellows seal Set point adjustment Positioning springs Bracket Fastening nuts Actuator Actuator stem Operating diaphragm Operating bellows Diaphragm plate Nut Nuts and bolts Control line connection (with screw joint with restriction for steam) Control line to be provided by operator (control line kit also available as accessory for connection directly at the valve body) Condensation chamber Filler neck Anti-rotation clip

EB 2512 EN

Design and principle of operation

1 2

19

3 4 5 6 7 5.1 12.1
Pillar turned 90 into plane of projection

18

17
DN 15 to 50

20 9 8 10 11 12 13 14 15 16

Actuators with metal bellows for 5 to 10, 20 to 28 and 10 to 22 bar

DN 65 to 100

Fig. 2 Sectional drawings: valve with diaphragm actuator and actuators with operating bellows (12.1)

EB 2512 EN

Installation

2. Installation 2.1 Assembly

Valve and actuator can be assembled before or after the control valve has been installed in the pipeline. Push the actuator (10) with the actuator stem (11) through the hole in the bracket (8) onto the spigot of the bellows seal (5.1). Align and secure it with the nuts (9, width across flats SW 17). For actuators with metal bellows in sizes DN 65 to 100, remove the bracket (8) from the valve and unscrew the pillar. Screw the pillar into the actuator flange. Push the actuator onto the valve and secure the pillar at the valve flange using nuts.

If the pipeline upstream and downstream of the valve is routed vertically upwards, an automatic water drainage (SAMSON Type 13E Steam Trap) is required. Make sure you choose a place of installation that allows you to freely access the regulator even after the entire plant has been completed. The regulator must be installed free of stress. If necessary, support the piping near the connections. Caution! Never attach supports directly to the valve or actuator. Do not install any devices (e.g. temperature regulators or shut-off valves) which restrict the cross-section of the pipe between the pressure tapping point and the control valve. If a bypass line is to be used, it must be connected downstream of the pressure tapping point. Install a shut-off valve in the bypass line.

2.2 Mounting position

Caution! Flush the pipeline thoroughly before installing the regulator to ensure that any sealing parts, weld spatter and other impurities carried along by the process medium do not impair the proper functioning of the valve, above all the tight shut-off. A strainer (SAMSON Type 2) must be installed upstream of the regulator (see section 2.4). Install the pressure reducing valve in a horizontal pipeline. On installing the valve, make sure the direction of flow corresponds with the arrow on the body. For media with a tendency to condensate, install the pipeline with a slight downward slope on both sides so that the condensate can drain properly.

Standard mounting position for medium temperatures above 0 C. Not permissible for millibar pressure regulators! Optional mounting position for gases and liquids up to medium temperatures of 80 C. Mandatory mounting position for millibar pressure regulators. Not permissible. Fig. 3 Mounting positions

EB 2512 EN

Installation

2.3 Control line, condensation chamber and screw joint with restriction
A control line must be provided in the form of a 3/8" pipe for steam and an 8 x 1 or 6 x 1 mm pipe for air/water. Control line kit: A kit for tapping pressure directly at the valve body is available as an accessory. Condensation chamber: A condensation chamber is required for liquids above 150 C as well as for steam. The mounting position of the condensation chamber is indicated by an adhesive label on the chamber itself as well as by an

arrow and the word "top" stamped onto the top of the chamber. This mounting position must be adhered to; otherwise the safe functioning of the pressure reducing valve cannot be guaranteed. Weld the line coming from the pressure tapping point to the 3/8" filler neck on the condensation chamber. The condensation chamber must always be installed at the highest point of the pipeline. Consequently, the control line between condensation chamber and actuator must also be installed with a downward slope. In this case, use a 3/8" pipe with screw gland. Connect the control line to the downstream line (p2) at least one meter away from the valve outlet (Fig. 4.1).

5 4 6

1 2 3 4 5 6 7 8

Shut-off valve Upstream pressure gauge 4.1 Control line connection (pipeline) Strainer Condensation chamber Caution! Millibar pressure regulators must be Pressure reducing valve installed vertically with the actuator on top. Downstream pressure gauge Shut-off valve 6 Steam trap

Min.1/2" 4.3 Connection below center of flange

8
4.2 Control line connection (manifold) Fig. 4 Installation examples with steam

Additional condensate head 4.4 Connection above center of flange

EB 2512 EN

Installation

If a manifold is located downstream of the pressure reducing valve (Fig. 4.2), connect the valve to the manifold, even if it is several meters away. If the downstream pressure line behind the valve is extended by means of a conical expansion piece, always connect the control line in the expanded section of the line. The control line must be welded at the side in the middle of the pipe, inclining at a ratio of approximately 1 : 10 up to the condensation chamber. If the control line connection is located below the center of the valve outlet flange, the condensation chamber must be located at the level of the outlet flange (Fig. 4.3). In this case, use a pipe which is at least 1/2" in size for the control line from the tapping point to the condensation chamber. When the control line is connected above the center of the valve outlet, install the condensation chamber at the level of the downstream pressure tapping point (Fig. 4.4). The additional pressure of the condensate head must be compensated for by adjusting the set point to a higher value. Needle valve: If the regulator tends to hunt, we recommend to install a needle valve in the control line.

2.5 Shut-off valve

We recommend to install a hand-operated shut-off valve both upstream of the strainer and downstream of the regulator to be able to shut down the plant for cleaning and maintenance, and when the plant is not used for longer periods of time.

2.6 Pressure gauge

To monitor the pressures in the plant, install a pressure gauge both upstream and downstream of the regulator. Note that the pressure gauge on the downstream side should not be installed upstream of the downstream pressure tapping point.

2.4 Strainer
The strainer must be installed upstream of the pressure reducing valve. Make sure the direction of medium flow corresponds with the direction indicated by the arrow on the strainer. The filter element must be vertically suspended. Remember to leave enough space to remove it.

EB 2512 EN

Operation

3. Operation 3.1 Start-up

Caution! For millibar pressure reducing valves (1200 cm2 actuator), the max. permissible differential pressure is 10 bar. The max. per missible pressure at the actuator must not exceed 0.5 bar. For regulating steam: Unscrew filler neck (19) on the condensation chamber. Using either the included plastic funnel or a jug, pour in water until it starts to overflow. Screw the filler neck back in and tighten it. The pressure reducing valve is now ready for operation. Open the hand-operated shut-off valves slowly to prevent water hammer. For regulating liquids: To start up the pressure reducing valve, open shut-off valves slowly. For actuators with an effective diaphragm area of 640 cm2, loosen the vent screw. Allow all the air to escape, then retighten it. For temperatures above 150 C, the necessary condensation chamber must first be filled with the process medium.

pressure, turning counterclockwise reduces it. The pressure gauge located on the downstream pressure side allows the adjusted set point to be monitored.

4. Maintenance Troubleshooting
The pressure reducing valve is maintenance free. Nevertheless, it is subject to natural wear, particularly at the seat, plug and operating diaphragm. Depending on the operating conditions, the regulator needs to be checked at regular intervals to avoid possible malfunctions. Details on faults and how to correct them can be found in the table on page 10. If a problem cannot be solved with the help of the information specified in the table, contact SAMSON.

3.2 Set point adjustment

The required downstream pressure is set by turning the set point adjustment (6) using an open-end wrench up to DN 50 with width across flats SW 19 and for DN 65 and larger with SW 22. Turning clockwise increases the downstream

Note! If a repair is performed by the plant operator, make absolutely sure that no torque is applied to the bellows seal (5.1) during assembly or disassembly. Otherwise, the metal bellows would be destroyed. When disassembling the valve, set the antirotation clip (20, Fig. 2 left) to "unlock". On reassembly set the clip back to "lock". Also observe the note on the bracket (8).

EB 2512 EN

Maintenance Troubleshooting

Caution! When working on the pressure regulator, make sure the relevant section of the pipeline is depressurized and, depending on the process medium, drained as well. For high temperatures, allow the regulator to cool down to ambient temperature before starting any work on it. The control line must be interrupted or shut off to avoid any hazards which could be caused by moving parts of the regulator. As valves are not free of cavities, remember that residual process medium might still be contained in the valve. This applies in particular to valve versions with a balancing bellows. It is recommended to remove the valve from the pipeline. Fault Pressure exceeds the adjusted set point Possible reasons

4.1 Replacing the operating diaphragm

If the downstream pressure deviates from the set point considerably, check if the diaphragm is leaking and, if necessary, replace it. 1. Shut down the plant by slowly closing the shut-off valves. Relieve the relevant section of the pipeline of pressure and, if necessary, drain it as well. 2. Unscrew the control line (17) and clean it. 3. Loosen the bolts (15) at the actuator and remove the cover plate. 4. Unscrew the nut (14) and lift off the diaphragm plate (13). 5. Replace the operating diaphragm (12) with a new one. 6. Proceed in the reverse order to reassemble the regulator. For start-up, proceed as described in section 3.1. Solution Clean the control line and screw joint with restriction Disassemble the regulator and exchange the damaged parts Rebuild the control lines, do not tap at pipe bends and necks Reinstall or exchange the condensation chamber, required size for 160 cm2 actuators: 0.7 l, for 320 cm2 and larger: 1.7 l Install larger screw joint with restriction at the diaphragm actuator

Pressure impulse on the actuator diaphragm not sufficient Seat and plug worn out by deposits or foreign particles Pressure tapped in wrong location When used to regulate steam: Condensation chamber improperly positioned or chamber too small Control response too slow

10

EB 2512 EN

Maintenance Troubleshooting

Pressure drops below the adjusted set point

Foreign particle blocks the plug Valve installed against direction of flow, see arrow on the body Pressure tapped in wrong location Valve or KVS value too small Control response too slow When used to regulate steam: Condensation chamber improperly positioned

Disassemble the regulator and exchange the damaged parts Check direction of flow, reinstall the valve Rebuild the control line Check sizing, install larger valve if necessary Install larger needle valve at the diaphragm actuator Reinstall the condensation chamber; see Fig. 3 for mounting position Exchange the damaged parts

Jolting control response Slow control response

Increased friction, e.g. due to foreign particles between seat and plug Restriction in the actuator screw joint too small Dirt in the control line

Install larger screw joint with restriction Clean the control line Check sizing, choose smaller KVS value if necessary Install smaller screw joint with restriction Choose an appropriate pressure tapping point Check sizing, install a flow divider when used to regulate steam and gases

Upstream pressure hunts

Valve too large Restriction in the actuator screw joint too large Inappropriate pressure tapping point

High noise emission

High flow velocity, cavitation

EB 2512 EN

11

Description of nameplates

5. Description of nameplates
Valve nameplates
2
SAMSON
bar DN PN p

1
No bar T

4
Kvs C

Made in Germany

DIN version

10

11

12

1 2 3 4 5 8 9 10 11 12

Valve type Model number Model number index Order number or date K85 value Nominal size Nominal pressure Perm. differential pressure Perm. temperature Body material

2
SAMSON
psi N p

3
psi T F

1
No Cv

4
Size Cl

Made in Germany

ANSI version

10

11

12

With ANSI version 5 Size 8 Perm. differential pressure 9 Perm. temperature (F) 10 Body material 11 C8 value (K85 x 1.17) 12 ANSI Class (pressure rating)

Actuator nameplate
1
SAMSON
DIN ANSI Type PN pmax No psi Size bar DN

2
psi bar

3
A

4
sq.in cm 2 psi bar
2002 0062

12

Made in Germany

7 8

10

11

1 2 3 4 5 6 7 8 9 10 11 12

Model number Model number index Order number or date Effective area Labeling acc. to DIN Labeling acc. to ANSI Maximum perm. pressure Nominal size Differential pressure Set point range Diaphragm material Year of manufacture

Fig. 5 Nameplates

12

EB 2512 EN

EB 2512 EN

13

Dimensions in mm and weights

6. Dimensions in mm and weights

DN Set point range bar L1 Length L PN 16 PN 40 Height H1 Height H3 0.005...0.03 Height H Actuator 0.025...0.05 Height H Actuator 0.05...0.25 Height H Actuator 0.1...0.6 Height H Actuator 0.2...1.2 Height H Actuator 0.8...2.5 Height H Actuator 2...5 Height H Actuator 4.5...10 Height H Actuator 8...16 Height H Actuator 0.005...0.05 0.05...0.6 0.2...2.5 2...16


15 130 220

20 150 256 335 55

25 160 278

32 180 314

40 200 337 390 72

50 230 380

65 290 464 471 510 100

80 310 510

100 350 556 570 525 120

435 D = 490 mm 435 D = 490 mm 445 D = 380 mm 445 D = 380 mm 430 D = 285 mm 430 D = 225 mm 410 465 D = 170 mm 410 465 D = 170 mm 410 465 D = 170 mm 28.5 22.5 16 12 29.5 23.5 18 13 33.5 29.5 23.5 18.5 37.5 31.5 25.5 21 A = 40 cm 41 35 29 24 57 51 45 40 64 58 52 47 67 61 56 A = 40 cm 585 600 A = 80 cm 585 600 485 A = 160 cm 585 600 480 A = 320 cm 605 620 500 A = 640 cm 600 620 500 A = 640 cm 620 635 A = 1200 cm 490 A = 1200 cm 620 635 610

Weight for cast iron PN 16  Approx. kg

+10 % for cast steel PN 40 and spheroidal graphite iron PN 25

14

EB 2512 EN

Customer inquiries

L1 L

H3

Conical expansion piece

H1 H max. 215

25

7. Customer inquiries
If you have any questions regarding the pressure reducing valve, please submit the following details (also see nameplate): Regulator type and nominal size Product and order number as specified on the nameplate Pressure upstream and downstream of the valve Flow rate in m3/h

  

  Has a strainer been installed?  Installation drawing

EB 2512 EN

15

SAMSON AG MESS- UND REGELTECHNIK Weismllerstrae 3 60314 Frankfurt am Main Germany Phone: +49 69 4009-0 Fax: +49 69 4009-1507 Internet: http://www.samson.de

EB 2512 EN

S/Z 2003-10

Accessories Intermediate Tank for Controllers Type 39-2 (2392), Type 41-23 (2412/2413) and Type 41-73 (2417/2413) and Actuators Types 2415, 2418, 2424, 2425, 2426, 2427 and 2429

1. Application To ensure proper functioning of the controller versions listed above, an intermediate tank is to be installed in each associated control line. This tank is intended to protect the operating diaphragm of the connected actuator when steam and liquids above 150 C are controlled.

Edition January 1995

Mounting and operating instructions EB 2595 E

2. Installation The control line is to be installed laterally at the pipe in the middle of the pipeline or distributor. This line is to be installed with a steady upward slope (1:10) towards the intermediate tank. The mounting position of the tank is indicated by a label marked with an arrow and the word "top" impressed on top of the tank. This mounting position is coercive to ensure safe operation of the controller. Weld the control line coming from the tapping point to the R 3/8 pipe socket of the intermediate tank. The intermediate tank must always be installed at the highest point of the control line. This means, the control line connecting the intermediate tank and the diaphragm chamber of the actuator is to be also installed with a downward slope.

3. Operation To place the intermediate tank into service, remove the filler plug at the tank and the vent screw at the diaphragm actuator. Then, use the enclosed plastics funnel tube or a can having a bent spout to fill water (in case of steam control) through the associated filler socket into the intermediate tank. Fill up water until it escapes at the vent hole. Tighten vent screw at the actuator and fill up water until it spills over at the filler socket of the tank. Reinstall filler plug and screw it tight. If liquids are controlled, fill up the intermediate tank with the corresponding medium.

SAMSON AG MESS- UND REGELTECHNIK Weismllerstrae 3 D-60314 Frankfurt am Main Postfach 10 19 01 D-60019 Frankfurt am Main Telefon (0 69) 4 00 90 Telefax (0 69) 4 00 95 07

EB 2595 E

S/C 01.95