Mounting and Operating Instructions EB 2512 EN
Contents
1. www samson de in all SAMSON product catalogs or on the back of these Mounting and Operating Instructions To assist diagnosis and in case of an unclear mounting situation specify the following details Type and nominal size of the valve Model number with index Upstream and downstream pressure Temperature and process medium Min and max flow rate strainer installed Installation drawing showing the exact location of the regulator and all the additionally installed components shut off valves pressure gauge etc 8 Dimensions Type 2412 Valve Type 41 23 Universal Pressure Reducing Valve c E Type 2413 Metal Bellows Actuator Type 2413 Diaphragm Actuator Fig 5 Dimensions EB 2512 EN 15 Customer inquiries Table 4 Dimensions in mm and weights Pressure reducing valve Valve size DN Length L Height H1 Forged steel 53 92 Other materials 72 Standard version with rolling diaphragm Height H3 Set point ranges 0 05 to 0 25 bar Height H 500 Actuator D 380 mm A 640 0 1 to 0 6 bar Height H 500 Actuator D 380 mm A 640 cm 0 2 to 1 2 bar Height H 480 Actuator OD 285 mm A 320 cm 0 8 to 2 5 bar 2 to 5 bar 4 5 to 10 bar Height H 485 Actuator Height H D 225 mm 160 465 Actuator Height H D 170 mm2. Installation 4 2 Mounting position Protect the regulator from icing up when controlling media that can freeze Remove the regulator from the pipeline when the plant is shut down if the regulator is not installed areas free from frost Flush the pipeline thoroughly before install ing the regulator to ensure that any sealing parts weld spatter and other impurities car ried along by the process medium do not im pair the proper functioning of the valve above all the tight shut off NOTICE Install a strainer e g SAMSON Type 2 upstream of the regulator Install the pressure reducing valve in hori zontal pipelines 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 If the pipeline upstream and downstream of the valve run vertically upwards an auto matic water drainage e g SAMSON Type 13 E Steam Trap is required Choose a place of installation that allows you to freely access the regulator even alter the entire plant has been completed The regulator must be installed free of stress If necessary support the pipe near the connecting flang es Standard mounting position for gases liquids and steam Not for millibar pressure regulator Alternative mounting position for gases and liquids at medium t
3. 3 Threaded holes Fastening nuts 10 Diaphragm actuator 11 Actuator stem 12 Operating diaphragm 12 1 Operating bellows 13 Diaphragm plate 14 15 Nuts and bolts 16 Control line connection 4 for steam including screw joint with restriction 17 Control line installed on site control line kit avail able for tapping the pressure directly at the valve body see T 2595 18 Compensation chamber 19 Filler plug 20 Anti rotation clip 0 I CO EB 2512 EN Installation LZ 22222221 ie P A N 77 SEZES PAA li ETD A ALL ALLE g re J 7 IIIIIG Lr ZZ p 29 T2727 and 10 to 22 bar Type 2413 Actuat r with metal bellows for 2 to 6 bar 5 to 10 bar 20 to 28 bar Metal bellows actuator for DN 65 to 100 Type 2412 Valve DN 65 to 250 1190 8790 1190 8789 Diaphragm Actuator 8 2 15 Compensation chamber 1190 8788 an Ww A A d SN ns 4 m en yA NN A NT 1190 8789 1190 8788 Gi DER N L PMI IAI IVIL ZILLI LLL LNA N DN 15 to 50 LI Z 74 RS number 4 BIS SSIS NN 9 9 9 4 Assignment of compensation chamber 18 to Functional diagram 160 80 40 Fig 1 Table 1 regulator Actuator area in EB 2512 EN
4. quest To ensure appropriate use only use the regulator in applications where the operating pressure and temperatures do not exceed the specifications used for sizing the regulator at the ordering stage The manufacturer does not assume any responsibility for damage caused by external forces or any other external factors Any hazards that could be caused in the regulator by the process medium operating pressure or by moving parts are to be prevented by taking appro priate precautions Proper transport storage installation operation and maintenance are as sumed EB 2512 EN Process medium and scope of application 2 Process medium and scope of application Pressure regulators for set points from 0 05 to 28 bar Valve nominal sizes DN 15 to 100 Nominal pressure PN 16 to 40 Suitable for liquids gases and vapors up to 350 The valve closes when the downstream pressure rises NOTICE The Type 41 23 Pressure Reducing Valve is not a safety valve If necessary a suitable overpressure protection must be installed on site in the plant section 2 1 Transportation and storage The regulator must be carefully handled transported and stored Protect the regulator against adverse influences such as dirt moisture or frost during storage and transportation When regulators are too heavy to be lifted by hand fasten the lifting sling at a suitable place on the valve body NOTICE Do not attach any lifting equipment slings or s
5. 49 69 4009 1507 samson samson de www samson de EB 2512 EN 2015 08 19 English
6. 80 cm 465 Actuator D 170 mm 40 cm 8 to 16 bar Height H 465 Actuator D 170 mm A 40 cm Weight for version with rolling diaphragm Set point ranges Special versio Set point ranges 0 05 to 0 6 bar 0 2 to 2 5 bar 16 bar 2 to 6 bar Weight based on cast iron 9 approx kg Height H 22 9 29 5 31 5 35 2359 25 5 29 n with metal bellows actuator 550 18 5 2 24 Actuator 5to 10 bar Height H 550 Actuator 10 to 22 bar Height H Actuator 538 20 to 28 bar Height H Actuator Weight for version with metal bellows actuator A 33 cm2 A 62 Based on cast iron 1 approx kg 16 5 17 9 20 9 21 5 1 10 9 for cast steel spheroidal graphite iron and forged steel 16 2512 Nameplate 9 Nameplate Nameplates are attached to the valve and the actuator Valve nameplate DIN version Valve type Model number with index Configuration ID Var ID Order number or date Kys coefficient Spring force Valve size Nominal pressure Perm differential pressure Perm temperature Body material ANSI version ANSI version 5 Nominal size 7 Spring force 8 Perm differential pressure 9 temperature F 10 Body material 11 Cy coefficient Ky x 1 17 12 AN
7. 6 Pressure gauge Install a pressure gauge both upstream and downstream of the regulator to monitor the pressures prevailing in the plant Install the pressure gauge on the downstream side be hind the downstream pressure tapping point not between the tapping point and the valve EB 2512 EN 5 Operation 5 1 See Fig 1 on page 7 Start up First start up the regulator after mounting parts Make sure the control line is open and correctly connected Fill the plant slowly with the process medium Avoid pressure surges Open the shut off valves first on the upstream pressure side Afterwards open all the valves on the con sumer side downstream of the regulator The pressure at the actuator must not exceed the permissible pressure on lesting the pressure of the plant see section 10 If necessary detach the control line and seal the openings with end plugs Alternatively install a shut off valve in the control line Make sure that the pressure rises si multaneously upstream and down stream of the regulator to avoid dam aging the balancing bellows Regulation of steam Unscrew filler plug 19 on the compensation chamber Use the included plastic funnel or a jug to pour in water until it starts to overflow Screw the filler plug 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 EB 2512 EN Ope
8. SI Class pressure rating Actuator nameplate DIN ANSI version Actuator area DIN ANSI Type Configuration ID Var ID ID number Max perm pressure Pexceed above the set point adjusted at the actuator DIN ANSI Valve size DIN ANSI Set point range DIN ANSI Diaphragm material Fig 6 Nameplates EB 2512 EN 17 Technical data 10 Technical data Table 5 Technical data All pressures in bar gauge Valve Nominal pressure Type 2412 PN 16 25 or 40 Nominal size DN 15 to 50 DN 65 to 80 DN 100 Max permissible differential pressure Ap 16 bar 25 bar 20 bar Max permissible temperature See pressure temperature diagram in gt T 2500 Valve plug Metal seal max 350 C PTFE soft seal max 220 C EPDM or soft seal max 150 NBR soft seal max 80 C 1 Leakage class according to 60534 4 Metal seal leakage class 0 05 of Ky coefficient Soft seal leakage class IV 0 01 of Kys coefficient Diaphragm actuator Set point ranges Type 2413 0 05 to 0 25 bar 0 1 to 0 6 bar 0 2 to 1 2 bar 0 8 to 2 5 bar 3 2 to 5 bar 4 5 to 10 bar 8 to 16 bar Max permissible temperature Gases 350 C however max 80 C at the actuator Liquids 150 C with compensation chamber max 350 C Steam with compensation chamber max 350 C Metal bellows actuator Effective area Set point ranges Set point spring Typ
9. Self operated Pressure Regulators Type 41 23 Universal Pressure Reducing Valve Type 41 23 Pressure Reducing Valve Mounting and Operating Instructions EB 2512 EN Edition July 2015 Definition of signal words DANGER Hazardous situations which if not Property damage message or mal avoided will result in death or seri function ous Injury R Note WARNING Additional information Hazardous situations which if not avoided could result in death or seri ous in SE jury P R ecommended action 2 EB 2512 EN 10 Contents General safety instructions Lecce eese eee seen e eere eene ettet ra teens etna 4 Process medium and scope of application eese 5 Transporlalion and SIONS ac scm docu deci UP e VO RU RE RU UR UR 5 Design and principle of operation 5 HVS RUAN eigenen 6 Assembly s REID DEN 6 POURING BOSI ON ee ae ee ee 8 Control line compensation chamber and needle valve 9 SEIS 10 10 Pre STEGE 10 OPONON ea E E 11 a E 11 Adjusting the set ol NET 11 ae TS 12 Cleaning and maintenanc
10. and downstream pressures acting on the plug are balanced Depending on the valve and actuator used the regulator can be upgraded to create a pressure reducing valve for low flow rates a steam pressure reducing valve or a pressure reducing valve with increased safety 4 Installation 4 1 Assembly See Fig 1 on page 7 Valve and actuator can be assembled before or after the valve has been installed in the pipeline Push the diaphragm actuator 10 with actu ator stem 11 through the hole in the cross beam 8 onto the spigots of the bellows 5 1 Align it and fasten with nuts width across flats 16 9 onto the valve flange ap prox 25 Nm For metal bellows actuators in DN 15 to 50 remove the crossbeam 8 from the valve Push the actuator stem 11 onto the spigots of the bellows 5 1 Align the pillars 8 1 and fasten with nuts width across flats 24 8 2 to the actuator max 60 Nm For metal bellows actuators in DN 65 to 100 remove the crossbeam 8 from the valve and unscrew the pillars 8 1 Screw the pillars into the threaded holes 8 3 of the actuator flange as far as they will go Push the actuator with actuator stem 11 onto the spigots of the bellows 5 1 Fasten the pillars with nuts width across flats 24 8 2 onto the valve flange max 60 Nm Valve body Seat Plug Balancing bellows Plug stem 1 Bellows Set point adjuster Positioning springs Crossbeam 1 Pillar 2 Nuts for pillar
11. be in stalled with a downward slope In this case use a 38 pipe with screw fittings IF the control line connection is located below the middle of the valve outlet flange arrange the compensation chamber at the same level as the outlet flange Fig 3 3 In this case use a pipe which is at least 2 in size for the control line from the tapping point to the compensation chamber If the control line is connected above the middle of the valve outlet flange install the compensation chamber at the same level as the downstream pressure tapping point Fig 3 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 installing a needle valve at the control line connection 16 in addition to the standard SAMSON screw joint with re striction 10 4 4 Strainer filter Install the strainer upstream of the pressure reducing valve The direction of flow must correspond to the arrow on the body The fil ter element must be installed to hang down wards or sideways for applications with steam Remember to leave enough space to remove the filter element 4 5 Shut off valve Install a hand operated shut off valve both upstream of the strainer and downstream of the regulator This allows the plant to be shut down for cleaning and maintenance and when the plant is not used for longer periods of time 4
12. e eese eese eere eene 13 Replacing the operating diaphragm cccccccscccssccessccessecesseeesecessessseeesaes 13 Customer d 15 DUCTS HONS Rr 15 een een 17 18 2512 EN 3 General safety instructions u General safety instructions The regulator is to be mounted started up serviced by fully trained and qualified personnel only the accepted industry codes and practices are to be observed Make sure employees or third persons are not exposed to any danger All safety instructions and warnings given in these mounting and operating instructions particularly those concerning installation start up and mainte nance must be strictly observed According to these mounting and operating instructions trained personnel refers to individuals who are able to judge the work they are assigned to and recognize possible dangers due to their specialized training their knowledge and experience as well as their knowledge of the applicable standards The regulators comply with the requirements of the European Pressure Equip ment Directive 2014 68 EU Devices with a CE marking have a declaration of conformity which includes information about the applied conformity as sessment procedure This declaration of conformity can be provided on re
13. e 2413 62 cm 2 to 6 bar 5 to 10 bar 33 cm 10 to 22 bar 20 to 28 bar 1 With oxygen max 60 C 2 Set point spring 4400 N Version with actuator with two diaphragms 1 to 2 5 bar Max permissible pressure at actuator Set point range Actuator with rolling diaphragm 0 1 to 0 6 bar 0 05 to 0 25 bar 4 5 to 10 bar 0 8 to 2 5 bar 0 2 to 12 bar 8 to 16 bar 2 to 5 bar Max permissible pressure above the set point adjusted at the actuator 0 6 bar 0 6 bar 1 3 bar 2 5 bar 5 bar 10 bar 10 bar Set point range Metal bellows actuator 2 to 6 bar 5 to 10 bar 10 to 22 bar 20 to 28 bar Max permissible pressure above the set point adjusted at the actuator 6 5 bar 6 5 bar 8 bar 2 bar 18 EB 2512 EN Note Conversion from chromate coating to iridescent passivation We at SAMSON are converting the surface treatment of passivated steel parts in our production As a result you may receive a device assembled from parts that have been subjected to different surface treatment methods This means that the surfaces of some parts show different reflections Parts can have an iridescent yellow or silver color This has no effect on corrosion protection For further information go to www samson de chrome en html EB 2512 EN 19 SAMSON AG 55 UND REGELTECHNIK Weism llerstraDe 60314 Frankfurt am Main Germany Phone 49 69 4009 0 Fax
14. emperature up to 80 C Prescribed mounting position for millibar pressure regulators Not for steam Not permissible 1 1 On request Permissible for regulators with fixed plug stem guide plus with medium temperature up to 80 C Not for steam Fig 2 Mounting position NOTICE Do not attach supports directly to the valve or actuator If a bypass line is to be used it must be con nected downstream of the pressure tapping point Install a shut off valve in the bypass line D Note Do not install any instruments e g temperature regulators or shut off valves that restrict the cross section of the pipe between the pressure tap ping point and the valve EB 2512 EN 4 3 Control line compensation chamber and needle valve Control line A control line must be provid ed at the site of installation e g a 38 pipe for steam or an 8 x 1 or 6x 1 mm pipe for air water Connect the control line to the downstream line p at least one meter away from the valve outlet Fig 3 1 If a manifold is locat ed downstream of the pressure reducing valve Fig 3 2 connect the valve to the manifold even if it is several meters away If the downstream line behind the valve is ex Installation tended by a conical expansion piece con nect the control line in the expanded section of the line Weld the control line at the side in the middle of the pipe inclining at a ratio of approximately 1 10
15. ions Details on faults and how to remedy them can be found in Table 3 WARNING N Before performing any work on the regulator make sure the relevant plant section has been depressurized and depending on the process medi um drained as well We recommend removing the valve from the pipeline When used at high temperatures al low the plant section to cool down to ambient temperature Disconnect or shut off the control line to prevent the risk of moving regula tor parts As valves are not free of cavities remember that residual pro cess medium might still be contained in the valve EB 2512 EN Cleaning and maintenance Make absolutely sure that no torque is applied to the bellows seal 5 1 during assembly or disassembly Otherwise the metal bellows will be destroyed On disassembling the valve push the anti rotation clip 20 in Fig 1 to entriegelt unlock Push it back again to verriegelt lock on reassembly See also the note on the crossbeam 6 1 Replacing the operating di aphragm If the downstream pressure deviates consid erably from the set point check if the dia phragm is leaking and if necessary replace it as follows Shut down the plant by slowly closing the shut off valves Depressurize the relevant section of the pipeline and if necessary drain it as well Unscrew the control line 17 and clean it Loosen the bolts 15 at the actuator a
16. nd remove the casing Unscrew the nut 14 and lift off the dia phragm plate 13 Replace the operating diaphragm 12 with a new one Proceed in the reverse order to reassem ble the regulator For start up proceed as described in section 5 1 13 Cleaning and maintenance Table 3 Troubleshooting Malfunction Pressure exceeds the adjusted set point Pressure drops be low the adjusted set point Jerky control response Slow control response Possible reasons Insufficient pressure pulses on the op erating diaphragm Recommended action Clean the control line and the screw joint with re striction Seat and plug worn down by deposits or foreign particles Disassemble the regulator and replace damaged parts Pressure tapped at the wrong place Reconnect control lines at a different place Do not tap pressure at pipe bends or necks With steam compensation chamber in the wrong position or too small Reconnect chamber at a different place or replace it see Table 1 and section 4 3 Control response too slow Foreign particles blocking the plug Valve installed against the flow see arrow on body Pressure tapped at the wrong place Valve or Ky coefficient too small Control response too slow With steam compensation chamber in the wrong position or too small Foreign particles blocking the plug Increased friction e g due to foreign particles between seat a
17. nd plug Restriction in the screw joint of the actuator dirty or too small Install larger screw joint at the diaphragm actuator Disassemble the regulator and replace damaged parts Check direction of flow Install valve correctly Reconnect control line at a different place Check valve sizing Install larger valve if neces sary Install larger screw joint at the diaphragm actuator Reconnect chamber at a different place or replace it see Table 1 and section 4 3 Disassemble the regulator and replace damaged parts Remove foreign particles Replace damaged parts Clean screw joint or install larger screw joint Dirt in the control line Clean the control line Downstream pressure hunts Valve too large Check valve sizing Select smaller Kys coefficient if necessary Restriction in the screw joint of the actuator too large Install smaller screw joint Pressure tapped at the wrong place Select better place for pressure tapping Loud noises 14 High flow velocity cavitation Check sizing Install flow divider with gases and steam EB 2512 EN Customer inquiries 7 Customer inquiries Contact SAMSON s After sales Service department for support when malfunctions or defects arise E mail address aftersalesservice samson de The addresses of SAMSON its subsidiaries representatives and service facilities world wide can be found on the SAMSON website
18. pressure at the pressure amp 12bar 97 x 117 mm 150 mm gauge downstream of the regulator 14 x 104 mm x 128 mm x2 168 mm for a precise set point adjustment 4 5 to 10 bar 5 9bar x 85 mm x 100 mm x 131 mm 7 3bar x 93 mm x 112 mm x2152 mm 101 x 123 mm 17 2 mm 5 3 Decommissioning x 83 x 7mm x 126mm Close first the shut off valve on the upstream 92 x 110 x 170 mm side of the valve and then on the down x 100 mm x 122 mm x 184 mm stream side of the valve Set point 8 to 2 5 bar 1 2 79 mm x 92 mm 117 mm 1 7 bar 89 106 mm 142 mm 2 1 99 121 mm 167 mm 2 to 1 2 bar 0 45 98 0 70 127 1 0 157 0 1 to 0 6 bar 0 23 bar x 98 mm 0 35 bar x 127 mm 0 48 bar x 157 mm 05 to 0 25 bar 0 10 bar x270 mm x 92 mm 0 15 bar x281 mm x 116 mm 0 20 bar x291 mm x2139 mm Set point Set point Set point Set point 12 EB 2512 EN 6 Cleaning and maintenance See Fig 1 on page 7 The regulator does not require any mainte nance Nevertheless it is subject to natural wear particularly at the seat plug and oper ating diaphragm Depending on the operating conditions check the regulator at regular intervals to avoid possible malfunct
19. ration Regulation of liquids To start up the pressure reducing valve open shut off valves slowly For temperatures above 150 C first fill the compensation chamber with the process medium 5 2 Adiusting the set point See Fig 1 on page 7 The required downstream pressure is set by turning the set point adjuster 6 using an open end wrench up to DN 50 with width across flats SW 19 and for DN 65 and larg er with SW 24 The set point of the stainless steel regulator must be adjusted using the rod included Turn clockwise to increase the downstream pressure and turn counterclock wise to reduce it The pressure gauge located on the down stream pressure side allows the adjusted set point to be monitored An adjustment of the set point can also be made by turning the set point adjuster until the distance x see Fig 4 is reached Set point adjuster 6 Fig 4 Set poin 11 Installation Table 2 lists the set points and their assigned distance x for the regulators and their vari ous set point ranges Note Note that only a rough set point ad justment is performed by turning the Table 2 Set point adjustment Dimension x set point adjustment until the distance Set point x is reached The special properties Nominal size DN range of the process medium and plant are 8 16bar 15 25 321050 65to 100 not taken into account in this case 10bar 89 mm x 106 mm x 133 mm Check the
20. up to the compensa tion chamber Control line kit A control line kit for tap ping pressure directly at the valve body is available as an accessories part from SAMSON Compensation chamber See Table 1 on page 7 A compensation chamber is re quired for liquids above 150 C as well as for steam NOTICE Always install the millibar pressure 3 1 Control line connection regulator upright with the actuator on top Min pipe diameter Shut off valve Upstream pressure gauge Strainer Compensation chamber 8 Steam trap 3 2 Control line connection in manifold Fig 3 Examples of installation with steam EB 2512 EN 5 Pressure reducing valve 6 Downstream pressure gauge 7 Shut off valve 3 3 Control line connection below the middle of the flange Additional condensate head 3 4 Connection above the middle of the flange Installation The mounting position of the compensation chamber is indicated by an adhesive label on the chamber itself as well as by an arrow and the word top stamped on 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 tap ping point to the 28 pipe socket on the chamber Install the compensation chamber at the highest point of the pipeline Conse quently the control line between compensa tion chamber and actuator must also
21. upports to mounting parts such as the adjusting screw or control line 3 Design and principle of operation See Fig 1 on page 7 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 separately and must be assembled according to the instructions in section 4 1 The pressure reducing valve is used to maintain the pressure downstream of the valve to an adjusted set point The process medium flows through the valve between seat 2 and plug 3 in the direction in dicated by the arrow on the body The position of the valve plug determines the flow rate and the pressure ratio across the valve The plug stem is sealed by a frictionless bellows EB 2512 EN 5 Installation 5 1 The downstream pressure p is trans mitted through the compensation chamber 18 and control line 17 to the operating diaphragm 12 where it is converted into a positioning force For actuator versions with a bellows the pressure is transmitted to the operating bellows 12 1 The positioning force is used to move the valve plug accord ing to the force of the positioning springs 7 The spring force is adjustable at the set point adjuster 6 Valves with Kys 4 and higher feature a balancing bellows 4 The up stream pressure acts on the outside of the bellows and the downstream pressure on the inside of the bellows As a result the forces produced by the upstream
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