Mounting and Operating Instructions EB 2549 EN
Contents
1. C NBR soft seal 80 C temperature Valve balanced by a diaphragm Leakage class according to IEC 60534 4 lt 0 05 of Ky coefficient Type 2425 Actuator 150 C 0 05 to 0 25 bar 0 1 to 0 6 bar 0 2 to 1 0 bar Set point ranges 0 5 to 1 5 bar 1 0 to 2 5 bar Max perm Effective diaphragm 320 cm 640 cm pressure at actu area ator Pressure 3 bar 1 5 bar Gases 80 C at the actuator Liquids 150 C with condensation chamber max 350 C Steam with condensation chamber max 350 C Max permissible temperature For oxygen max 60 C 2 Set point ranges above 2 5 bar see T 2552 Type 2335 Excess Pressure Valve 18 EB 2549 EN SAMSON AG MESS UND REGELTECHNIK Weism llerstra e 3 60314 Frankfurt am Main Germany Phone 49 69 4009 0 Fax 49 69 4009 1507 samson samson de www samson de EB 2549 EN 2015 04 09 English Conversion from chromate coating to iridescent passivation 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 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 For2. ex changing the entire actuator assembly There fore we recommend contacting us if you want to change the set point range EB 2549 EN 5 3 Decommissioning Close first the shut off valve on the upstream side of the valve and then on the downstream side of the valve 6 Maintenance and trouble shooting If the upstream pressure deviates considerably from the set point check the control line for blockage and check the diaphragm for leak age In case of other causes such as a damaged seat or plug we recommend contacting SAM SON s After sales Service Department see section 8 If the diaphragm is damaged proceed as de scribed in section 6 1 WARNING Risk of scalding due to hot process medium escaping uncontrolled Allow the regulator to cool down be fore depressurizing and draining it and remove it from the pipeline 6 1 Replacing the operating dia phragm See Fig 1 and Fig 2 Shut down the plant by slowly closing the shut off valves Depressurize the relevant sec tion of the pipeline and if necessary drain it as well EB 2549 EN Maintenance and troubleshooting The actuator can be removed from the valve without having to remove the valve from the pipeline However in this case do not forget that the actuator cone seals off the bellows housing Consequently the process medium will drain out of the valve on removing the ac tuator 1 Relieve the spring assembly of tension by turning the set
3. 260 1400 mm Actuator D 380 mm A 640 cm Height H 990 1130 mm 1120 1260 mm 1260 1400 mm Actuator D 380 mm A 640 cm Height H 990 1130 mm 1120 1260 mm 1260 1400 mm Actuator D 380 mm A 640 cm Height H 940 1080 mm 1070 1210 mm 1210 1350 mm Actuator D 285 mm A 320 cm Height H 940 1080 mm 1070 1210 mm 1210 1350 mm Actuator D 285 mm A 320 cm Weight approx valve with actuator for cast iron PN 16 0 05 to 1 0 135 kg 116 kg 0 5 to 1 5 1 to 2 5 1 10 for cast steel spheroidal graphite iron and stainless steel 0 05 to 0 25 0 1 to 0 6 0 2 to 1 0 0 5 to 1 5 1 0 to 2 5 Set point ranges in bar Fig 5 Dimensions Type 2422 2424 Balanced by a bellows 16 EB 2549 EN Dimensions Type 2422 2425 Balanced by a diaphragm Dimensions in mm and weights in kg Nominal size DN 125 Length L 400 mm Height H 720 mm Height H2 145 mm Weight actuator with valve approx 0 05 to 1 bar 80 kg 0 5 to 2 5 bar 75 kg Fig 6 Dimensions Type 2422 2425 Balanced by a diaphragm EB 2549 EN 17 Technical data 10 Technical data Type 2422 Valve Nominal pressure PN 16 25 or 40 Nominal size DN 125 DN 150 DN 200 DN 250 Valve balanced by a Metal seal 350 C PTFE soft seal 220 C EPDM or FPM soft seal Max permissible _ bellows 150
4. 5 balanced by a bellows EB 2549 EN Installation Type 2422 Valve balanced by a diaphragm Type 2425 Actuator 5 1 Balancing diaphragm Pi Upstream pressure Pr Downstream pressure Fig 2 Functional diagram of Type 2422 2425 balanced by a diaphragm A Installation gt Place the actuator on the bellows housing l and carefully screw it in as far as it will ug bang go Make sure the control line connection 4 1 Assembly points toward the upstream pressure side gt Hold the actuator and fasten it to the bel Valve and actuator can be assembled before lows housing using the coupling nut 7 or after the valve has been installed in the pipeline gt Relieve the positioning springs of tension by turning the set point adjuster 13 8 EB 2549 EN Installation 4 2 Mounting position Direction of flow must match the direction l l l indicated by the arrow on the body Select the installation location making sure that the regulator is installed at a distance of Install the regulator free of stress If nec at least six times the nominal size DN away essary support the pipeline near to the from pipe fittings or instruments that cause connecting flanges Do not attach sup flow turbulence e g pipe bends manifolds ports directly to the valve or actuator pressure measuring points or other valves Install a strainer upstream of the regula They can change the flow conditions which tor may lead to
5. Self operated Pressure Regulators Type 2422 2425 Excess Pressure Valve Type 2422 2425 Excess Pressure Valve Mounting and Operating Instructions EB 2549 EN Edition April 2014 Definition of signal words DANGER j NOTICE Hazardous situations which if not Property damage message or mal avoided will result in death or serious function injury a aa Note WARNING Additional information Hazardous situations which if not avoided could result in death or seri ous inj UP jury P R ecommended action 2 EB 2549 EN Contents 1 2 2 1 3 4 4 1 4 2 4 3 4 4 4 5 4 6 4 7 5 5 1 5 2 5 3 6 6 1 7 8 9 10 Contents Page General safety instructions cssccsssscessccssscessccssecssssccssscsesscessscesssesseseesss 4 Process medium and scope of application ssccssscssscsssccssscessscessecessees 5 Transportation and storage nennen 5 Design and principle of operation ccsscssscsssscssssssccsscsssssssscsssessessenseees 6 stalan oeno EE 8 SS e Van ea ee IE A N NAAN OEE NE T A 8 Mounting position uses een 9 NO on USEC al an ne re 9 Control line condensation chamber and needle valve 000000000000 10 EE a een ee ee 11 SOFON Vale E E EE AE E E T 11 Pressure gAUge ne rear ee 11 ODETI NO 1 peress aO 12 Soa e ann ee E A A E E E A EN 12 Adjusting the set Do nee een 12 Decommi OH E ee teen 13 Maintenance and troubleshooting ssccssssc
6. an instable control process espe Protect the regulator from icing up when cially in applications with gases air or steam controlling media that can freeze If nec Contact SAMSON to obtain the TV SK 17041 essary depressurize and drain the regu documentation which contains more details on lator and remove it from the pipeline installation requirements while the plant is shut down 4 3 Notes on installation Install the excess pressure valve in horizontal pipelines Flush the pipeline thoroughly before in stalling the regulator to ensure that no impurities impair the proper functioning of the valve above all the tight shut off 1 Shut off valve 5 Downstream pressure 2 Upstream pressure gauge gauge 6 Bypass piping 3 Strainer filter p Upstream pressure A Type 2422 2425 p Downstream pressure Fig 3 Sample application Excess Pressure Valve EB 2549 EN 9 Installation Mounting position Valve balanced by a bellows diaphragm Actuator facing downward el f amp _ Pressure testing of the plant The pressure must not exceed the maximum permissible pressure of the regulator and plant on testing the pressure of the plant when the regulator is already installed An excessive test pressure can damage the operating diaphragm in the actuator j NOTICE Uncontrolled excess pressure in the plant may damage the operating dia phragm The maximum permissible pressure at the actuator must not exceed the p
7. cssssccsssccsssecesssesesssscessseeesnes 13 Replacing the operating diaphragm ccccccccscccsseccsseeessecesseeeseeesseeeseeeaes 13 Name plate een euer a een 14 CUSIOMIEN SERVICE VORRERRENERRPRRREENEERNLERER EEE ERERNEEFEEEEEEBFEUERERREEESENUNEENFEREREEEE SEE OBERE 15 Dimensions aussen nein ernennen 16 Technical Oddset 18 EB 2549 EN 3 General safety instructions General safety instructions The regulator must be mounted started up or 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 97 23 EC Devices with a CE marking have a declaration of conformity which includes information about the applied conformity assess ment procedure This declaration of conformity can be provided on request To ensure appropriate use onl
8. e DIN ANSI Set point range DIN ANSI Diaphragm material Fig 4 Nameplates 14 EB 2549 EN Customer service 8 Customer service If malfunctions or defects occur contact the SAMSON After sales Service Department for sup port The addresses of SAMSON AG its subsidiaries representatives and service facilities world wide can be found on the SAMSON website in all SAMSON product catalogs or on the back of these Mounting and Operating Instructions Please send your inquiries to service samson de To assist diagnosis specify the following details see section 7 Type and nominal size of the valve Model number and configuration ID Var ID Order number or date Upstream and downstream pressure Temperature and process medium Min and max flow rate in m3 h Isa strainer installed Installation drawing showing the exact location of the regulator and all the additionally installed components shut off valves pressure gauge etc EB 2549 EN 15 Dimensions 9 Dimensions Type 2422 2425 Balanced by a bellows Dimensions in mm and weights in kg The values in parentheses apply to temperatures from 220 to 350 C Nominal size DN 125 DN 150 DN 200 DN 250 Length L 400 mm 480 mm 600 mm 730 mm Height H1 460 600 mm 590 730 mm 730 870 mm Height H2 145 mm 175 mm 235 mm 260 mm Height H 990 1130 mm 1120 1260 1
9. ed these regulators can have a leakage rate of lt 0 05 of the Kys coefficient Overpressure protection must be installed in the plant WARNING Risk of injury and property damage due to high pressure in the plant 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 excess pressure valve against adverse influences such as dirt moisture or frost during storage and transpor tation When regulators are too heavy to be lifted by hand fasten the lifting sling at a suitable place on the valve body WARNING Incorrectly attached lifting slings or supports Risk of injury and property damage due to valve falling Securely fasten slings or supports to the valve body and secure against slipping EB 2549 EN 5 Design and principle of operation 3 Design and principle of op eration See Fig 1 and Fig 2 The Type 2422 2425 Excess Pressure Valve consists of the Type 2422 Valve and the Type 2425 Actuator The Type 2422 Valve is available either balanced by a bellows or a diaphragm The excess pressure valve is used to maintain the pressure upstream of the valve to an ad justed set point The valve opens when the up stream pressure rises The medium flows through the valve in the di rection indicated by the arrow The position of the plug 3 determines the flow rate across the area re
10. further information go to www samson de chrome en html
11. h a downward slope In this case use a pipe with screw fittings If the control line connection is located below the middle of the valve outlet flange arrange the condensation chamber at the same level as the outlet flange In this case use a pipe which is at least 2 in size for the control line from the tapping point to the condensation chamber If the control line is connected above the mid dle of the valve outlet flange install the con densation chamber at the same level as the upstream pressure tapping point The addi EB 2549 EN tional pressure of the condensate head must be compensated for by adjusting the set point to a higher value Control line kit A control line kit for tapping pressure directly at the valve body is available as an accessories part from SAMSON for set points 0 8 bar See T 2595 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 on the top of the chamber This mounting position must be adhered to otherwise the safe functioning of the excess pressure valve cannot be guaranteed Needle valve If the regulator tends to hunt install a needle valve at the control line con nection 18 in addition to the standard SAMSON screw joint with restriction 4 5 Strainer I
12. leased between plug and valve seat 2 The plug stem 4 with the plug is connected to the top diaphragm stem 8 of the actuator 10 The upstream pressure p is regulated by the positioning springs 11 and the set point ad juster 13 When relieved of pressure the valve is closed by the force of the set point springs The upstream pressure p to be controlled is tapped upstream of the valve and transmitted over the control line to the operating dia phragm 9 where it is converted into a posi tioning force This force is used to move the valve plug according to the force of the posi tioning springs When the force resulting from the upstream pressure p rises above the ad justed set point the valve opens proportional ly to the change in pressure The principle of operation of the Type 2422 2425 Excess Pressure Valve bal anced by a bellows or diaphragm only differs concerning the pressure balancing The valves balanced by a diaphragm have a balancing diaphragm 5 1 instead of a bellows 5 In both cases the forces created by the upstream and downstream pressures that act on the valve plug are balanced out The valves can be supplied with flow divider St or St Ill The valve seat must be replaced on retrofitting the flow divider The control of vapors and liquids above 150 C is only possible with a Type 2422 Valve balanced by a bellows In this case condensation chamber 20 is already in stalled in the con
13. nstall the strainer upstream of the excess pres sure valve see Fig 3 The direction of flow must correspond to the arrow on the body The filter element must be installed to hang downwards or sideways for appli cations with steam vy Tip K Remember to leave enough space to remove the filter element EB 2549 EN Installation 4 6 Shut off valve Install a hand operated shut off valve both up stream 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 see Fig 3 4 7 Pressure gauge Install a pressure gauge both upstream and downstream of the regulator to monitor the pressures prevailing in the plant see Fig 3 Install the pressure gauge on the upstream side in front of the pressure tapping point 11 Operation 5 Operation See Fig 1 and Fig 2 5 1 Start up First start up the regulator after mounting all 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 Af terwards open all the valves on the consum er side downstream of the regulator Regulation of steam Observe the following points for applications with steam Before start up all pipes conveying the process medium must be completely drained and dry to pre
14. point adjuster 13 counter clockwise 2 Unscrew the control line and clean it 3 Undo the coupling nut 7 and remove the actuator 4 Unscrew the set point adjuster 13 Re move bearing bushing spring s and spring plate 5 Remove nuts and bolts 15 Lift the top cover plate off the actuator stem 6 Pull the diaphragm stems together with the diaphragm plates and the diaphragm out of the lower diaphragm case 7 Hold the bottom nut 16 stationary using a socket wrench and unscrew the top dia phragm stem by loosening the nut 8 1 the nut is sealed with paint 8 Take off the top diaphragm plate 17 Re place the operating diaphragm 9 with a new one Proceed in the reverse order to reassemble the regulator For start up proceed as described in section 5 1 13 Nameplate 7 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 set point range Nominal size Nominal pressure Perm differential pressure Perm temperature Body material ANSI version ANSI version 5 Valve size 7 Spring force 8 Perm differential pressure 9 Perm temperature F 10 Body material 11 Cy coefficient Kys x 1 17 12 ANSI class pressure rating DIN ANSI version Actuator nameplate Effective area DIN ANSI Type Configuration ID Var ID ID number Valve siz
15. res sure specified in Table 1 Table 1 Max perm pressure at actuator Actuator area 640 cm 320 cm Max perm pressure 1 5 bar 3 bar To prevent damage to the diaphragm take one of following precautions Remove the regulator from the pipeline or isolate the regulator in the pipeline and install a bypass see Fig 3 or Detach the control line and seal the openings with end plugs or Install a shut off valve in the control line 10 4 4 Control line condensation chamber and needle valve Control line A control line must be provided at the site of installation e g a s pipe for steam or an 8 x 1 or 6 x 1 mm copper pipe for air or water Connect the control line to the upstream line p at least one meter away from the valve in let If a manifold is located upstream of the ex cess pressure valve connect the valve to the manifold even if it is several meters away If the upstream line is extended by a conical ex pansion piece connect the control line in the expanded section of the line Weld the control line at the side in the middle of the pipe in clining at a ratio of approximately 1 10 up to the condensation chamber Weld the line coming from the pressure tap ping point to the 7s pipe socket on the cham ber Install the condensation chamber at the highest point of the pipeline Consequently the control line between condensation cham ber and actuator must also be installed wit
16. trol line The needle valve 18 in the control line is open and lead sealed Before start up fill the condensation chamber with the process medium at the filling opening 21 until it overflows 1 Only in combination with a control line kit Otherwise the condensation chamber must be ordered separately see T 2595 EB 2549 EN Type 2422 Valve balanced by a bellows Design and principle of operation BIZZZZH NSS Type 2425 Actuator Type 2422 Valve Seat exchangeable Plug Plug stem Actuator stem Balancing bellows Bellows housing Vent screw 640 cm2 bellows housing Vent screw connection to actuator SSNAN o N LA NNN Gp a IM L ERS A A i ER Vf S N N i ZZ j zZ SS Vi PI IR SY bz 7 KY N A ez I i PTZ Lea j SIIIYZ rN wl IN eee SS 77 SA i j 9 Coupling nut Top diaphragm stem Nut Operating diaphragm Type 2424 Actuator Positioning springs Set point adjuster Bottom diaphragm stem Nuts and bolts Nut Diaphragm plate R 2 S FLI ZARA F rc Control line connection for steam including screw joint with restriction and needle valve Control line Condensation chamber for tem peratures above 150 C and for steam Filling opening with plug Upstream pressure Downstream pressure Fig 1 Functional diagram of Type 2422 242
17. vent steam ham mering Before start up fill the condensation chamber with water at the filling opening 21 until it overflows Screw the plug back in Slowly start up the plant and allow time for the pipes and valves to warm up Air and condensate must be allowed to es cape from the plant Install steam trap e g SAMSON Type 13 E or air vent for steam op erated systems e g SAMSON Type 3 at a suitable location Regulation of liquids To start up the excess pressure valve open shut off valves slowly Undo the vent screw 6 1 in 640 cm actuators until all the air has escaped Tighten the screw again 12 For temperatures above 150 C first fill the condensation chamber with the process medi um 5 2 Adiusting the set point Adjust the required upstream pressure by turning the set point adjuster 13 Turn clockwise U The upstream pressure is increased high er pressure set point Turn counterclockwise O The upstream pressure is reduced lower pressure set point When the force resulting from the upstream pressure p rises above the adjusted set point the valve opens proportionally to the change in pressure er Tip Monitor the adjusted set point pres sure at the pressure gauge on the up stream pressure side Changing the set point range The set point range is determined by the size of the actuator and its positioning springs The set point range can only be changed by
18. y 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 Note I Non electric actuators and control valve versions do not have their own potential ignition source according to the ignition risk assessment stipulat ed in EN 13463 1 2009 section 5 2 even in the rare incident of an op erating fault Therefore they do not fall within the scope of Directive 94 9 EC For connection to the equipotential bonding system observe the requirements specified in section 6 3 of EN 60079 14 VDE 0165 Part 1 EB 2549 EN Process medium and scope of application 2 Process medium and scope of application Pressure regulator for liquids gases and vapors up to 350 C For controlling the upstream pressure p to the adjusted set point The valve opens when the upstream pressure rises The upstream pressure is transmitted to the actuator over a control line that must be installed on site The pressure regulators are not shut off devices guaranteeing tight shut off When clos
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