Mounting and Operating Instructions EB 2528 EN
Contents
1. gt Valve body Seat Plug Plug stem Diaphragm plate with operating diaphragm Actuator housing Set point spring Set point adjuster Control line connection G tapped connection for upstream pressure Cap 1 2 4 5 6 7 8 9 1 Fig 2 Design and principle of operation Type 2408 Excess Pressure Valve EB 2528EN 5 Installation 2 2 Strainer Install a strainer upstream of the regulator Fig 3 Install the strainer with the direction of flow matching the arrow on the body Make sure the filter element is vertically sus pended Remember to leave enough space to remove it 2 3 Shut off valve Install a hand operated shut off valve both upstream of the strainer and downstream of the regulator Fig 3 to be able to shut down the plant for cleaning and maintenance and when the plant is not used for longer periods of time min 3 x DN ud 2 4 Pressure gauge To monitor the pressures in the plant install a pressure gauge both upstream and down stream of the regulator Fig 3 2 5 Control line G 14 tapped connection 9 at the actuator housing Install a control line with at least 6 mm inside diameter on site preferably an 8 1 mm pipe made of steel or stainless steel Always attach the control line connection for pressure tapping directly to the tank or vessel as the medium is fully expanded and free of turbulence at this point 10 slope towards pressure2. General safety instructions Observe the following instructions on installation start up and operation of the regulator for your own safety The regulator is to be mounted started up or serviced by fully trained and qualified personnel only observing the accepted industry codes and practices Make sure employees or third persons are not exposed to any danger All safety instructions and warnings in these mounting and operating instructions particularly those concerning assembly start up maintenance must be observed According to these mounting and operating instructions trained personnel is referred to as 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 regulator fulfils the requirements of the European Pressure Equipment Directive 97 23 EC 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 specified in the order that the valve sizing data are based on The manvfacturer does not assume any responsibility for damage caused by external forces or any other external influence Any hazards that could be caused in the regulator by the process medium the operating pressure or by moving parts are to be prevented by means of the appropriate measures
3. Proper shipping and storage are assumed Note Non electric valve versions whose bodies are not lined with an insulating material coat ing do not have their own potential ignition source according to the risk assessment stipulated in EN 13463 1 2001 section 5 2 even in the rare incident of an operating fault Therefore such valve versions do not fall within the scope of Directive 94 9 EC EB2528EN 3 Design and principle of operation 1 Design and principle of opera 2 Installation tion See also Fig 2 page 5 See also Fig 2 page 5 The process medium flows through the valve in the direction indicated by the arrow on the body The position of the valve plug 3 deter mines the flow rate across the area released between the valve s plug and seat 2 In pressureless state control line not con nected or no pressure applied the valve is closed by the force of the set point springs 7 The upstream pressure p to be controlled is tapped upstream of the regulator Using an external control line this pressure is transmit ted to the tapped connection 9 on the actua tor housing 6 where it is converted into a po sitioning force by the diaphragm plate with operating diaphragm 5 This positioning force is used to move the plug stem 4 and thus the valve plug depending on the force of the set point springs 7 The spring force can be adjusted on the set point adjuster 8 When the force resulting from the upstream
4. tapping min 5 x DN Fig Sample installation 6 2528 EN Type 2408 Shut off valve Pressure gauge upstream pressure Strainer Pressure gauge downstream pressure When tapping the pressure at a straight pipe line section observe a minimum distance of at least twice the nominal valve size to the regulator Connect the control lines to the side or top of the main horizontal pipeline If possible in stall the tapping connection in a pipe expan sion Install other fittings that may cause flow turbu lence e g shut off valves restrictions bows bends or branches at an appropriate dis tance to the control line connection at least three times the nominal valve size Note If the gas to be controlled contains moisture condensate may form in the control line which can damage the regulator To al low the gas to flow back into the tank or pipe line install the control line with a downward slope of approx 10 towards the pressure tapping point 3 Operation 3 1 See also Fig 2 page 5 Start up NOTICE Do not start up the regulator before all com ponents have been installed Make sure the control line is free of dirt or other contaminations that may impair the proper medium flow Connect the line properly Operation We recommend to open shut off valves slowly from the downstream side Avoid pressure surges NOTICE The max permissible pressure at the operat ing dia
5. Self operated Pressure Regulators Excess Pressure Valve Type 2408 Fig 1 Type 2408 Excess Pressure Valve Mounting and Operating Instructions EB 2528 EN Edition June 2010 Contents Contents Page Design and principle 4 Process medium application range versions A 4 Mounting position wa RR v mom hp UD 3 4 DIGIC 6 Shut off valve 2 2222 oo oo 6 Pressure 6 x N EEE Er EEE 6 S lp Cv 7 a oe ee a 7 Adjusting the set point 7 Decommissioning o a 8 Maintenance and troubleshooting 8 Pressure fluctuations oo oo 8 9 SOIVICE 4 e u 9 4 Ro JOY X O4 9 Technical s s ee e us saw s Hee 10 DIMENSIONS as 9 u u 2 0 00 9 9 as san nu P UE RO E 11 Definitions of the signal words used in these instructions CAUTION Note Indicates supplementary explanations Indicates a hazardous situation which if not information and tips avoided could result in minor or moderate injury NOTICE Indicates a risk of property damage 2 2528 EN Safety instructions
6. Soft seal at least class IV 5 to 15 mbar 10 to 30 mbar 25 to 60 mbar 50 to 200 mbar 100 to 1000 mbar 20 to 60 C Set point ranges 1 Only in conjunction with 100 to 1000 mbar set point range 10 EB 2528 EN Dimensions 8 Dimensions Flanged body made of Body with screwed ends spheroidal graphite iron made of stainless steel Table 2 Dimensions in mm Connection G 1 Female thread Length L 90 Width across flats SW 46 Height H3 45 540 Height H 360 15 mbar Actuator Actuator D 490 mm actuator area A 1200 cm 10 to Height H 360 30 mbar Actuator Actuator D 380 mm actuator area A 640 cm Height H 360 Actuator Actuator D 285 mm actuator area A 320 cm Height H 360 Actuator Actuator D 285 mm actuator area A 320 cm Height H 360 Actuator Actuator D 225 mm actuator area A 160 cm 25 to 60 mbar 50 to 200 mbar 100 to 100 mbar Approx weight 5 to 60 mbar set point range 17 18 in kg 50 to 1000 mbar set point range 132 Fig 6 Dimensions 2528 11 SAMSON AG MESS UND REGELTECHNIK Weism llerstraBe 3 60314 Frankfurt am Main Germany Phone 49 69 4009 0 Fax 49 69 4009 1507 Internet http www samson de EB 2528 EN S Z 2010 08 Conversion from chromate coating to iridescent passivation D Conversion from chromate coating to iridescent passivation We at SAMSON
7. 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 be en subjected to different surface treatment methods This means that the surfaces of so me 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
8. or connection thread G Fig 5 Nameplate 6 Service If malfunctions or defects occur contact the SAMSON After sales Service for support The addresses of SAMSON AG its subsidiar ies representatives and service facilities worldwide can be found on the Internet at www samson de in a SAMSON product cat alog or on the back of these mounting and operating instructions Include the following details when making in quiries Type and nominal size of the regulator Configuration ID Var ID Upstream and downstream pressures Temperature and process medium Min und max flow rates Has a strainer been installed Kys coefficient Set point range in bar Nominal pressure PN Installation drawing indicating the exact location of the regulator and all addition ally mounted units shut off valves pres sure gauges etc EB2528EN 9 Technical data 7 Technical data Table 1 Technical data Connection Nominal size G 4 and G 1 DN 15 and DN 25 Stainless steel Spheroidal graphite iron Nominal pressure PN 25 Control line connection for 8 x 1 mm pipe Kys coefficients 0 25 1 02 5 3 205 0U Max perm differential pressure Ap 6 bar Max perm pressure at the actuator Actuator area A 1200 cm 0 5 bar Actuator area A 640 cm 1 bar Actuator area A 320 cm 2 bar Actuator area A 160 cm A bar Permissible temperature range of the medium Leakage class acc to DIN EN 60534 4
9. phragm must not exceed 0 5 bar with 1200 cm 1 bar with A 640 2 2 bar with A 320 cm and 4 bar with A 160 cm Make sure this pressure is not exceeded par ticularly when pressure testing the plant with the regulator installed or when starting up the plant 3 2 Adjusting the set point Adjust the desired set point by tensioning the set point springs using the set point adjuster SW 27 34 adjustment screw Remove the cap 10 Turn the adjustment screw using a socket wrench with width across flats SW 27 Turn the adjuster clockwise U to increase the set point and counterclockwise U to reduce it Remount the cap Adjustment screw SW 27 _ 2 2 Fig 4 Set point adjustment view from top 2528EN 7 Maintenance and troubleshooting Check the adjusted set point on the pressure gauge installed upstream of the regulator Fig 3 3 3 Decommissioning We recommend to close the upstream shut off valve before closing the shut off valve in stalled downstream of the regulator 4 Maintenance and trouble shooting The pressure regulator 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 in tervals to detect and remove possible mal functions CAUTION For installation and maintenance work on the regulator make sure
10. pressure p exceeds the adjusted set point the valve opens proportionally to the change pressure 1 1 Process medium application range versions Excess pressure valve for set points between 5 mbar to 1000 mbar for gases at tempera tures from 20 to 60 C Valves with flanged body in DN 15 and DN 25 as well as with G v G 34 and G 1 fe male thread EB 2528 EN NOTICE Install a strainer e g SAMSON Type 2 NI upstream of the regulator refer to sec tion 2 2 Make sure the regulator is mounted free of stress If necessary support the piping near the connecting flanges Never attach supports directly to the valve or actuator 2 1 Mounting position Mounting position preferable Install the regulator in a horizontal pipeline with the actuator housing and set point adjuster pointing ver tically up The direction of flow must correspond to the arrow on the body a the control line with a downward slope of pee 10 towards the tapping oint to allow condensed liquid to flow ba into the tank or pipeline Other mounting positions Install the regulator in a vertical pipeline with the actuator housing and set point adjuster pointing to the side Note Higher system deviations may occur in this mounting position Make sure the direction of flow matches the arrow on the body from bottom to top Installation zu A AL j cm a a AY AY A A j nm 39
11. the relevant plant sec tion has been depressurized and depending on the process medium drained as well We recommend to remove the regulator from the pipeline If necessary allow the regulator to cool down to reach ambient temperature before starting any work on it Disconnect or shut off the control line to avoid any hazards that could be caused by moving regulator parts As valves are not free of cavities remember that residual process medium might still be contained in the valve 8 EB2528 EN 4 1 Pressure fluctuations NOTICE Pressure fluctuations oscillation may dam age the regulator and plant As a result pre vent them from occurring or remove their cause immediately To stop oscillation from occurring the follow ing actions may be helpful Check the pressure tapping point at the control line refer to section 2 5 if neces sary move the tapping point Screw a SAMSON restriction into the sleeve for the tapped connection 9 or der no 1991 7114 for 1200 and 640 cm order no 1991 7113 for 320 and 160 cm Check the regulator s sizing data If nec essary change the Kvs coefficient seat di ameter or diaphragm area Contact SAMSON refer to section 6 if the problems persist Nameplate CELL X SAMSON Legend 1 Configuration ID VAR ID 2 Manufacturing data 3 Type designation 2408 A Max perm differential pressure in bar Max perm temperature in C Nominal size DN
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