Mounting and Operating Instructions EB 2517 EN
Contents
1. 390 Height H3 72 Standard version with rolling diaphragm 0 05 to 0 25 bar Height H 500 Actuator D 380 mm A 640 cm 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 O 8 to 2 5 bar 2 Height H Actuator 485 D 225 A 160 cm 2 to 5 bar Set point ranges Height H Actuator 465 D 170 mm 80 cm 4 5 to 10 bar Height H 465 Actuator D 170 mm A 40 cm 8 to 16 bar Height H 465 Actuator D 170 mm 40 cm Weight for version with rolling diaphragm 0 05 to 0 6 bar 0 2 to 2 5 bar 5 2to 16 bar point ranges 5 Special versio 2 to 6 bar Height H Weight based on cast iron approx kg 22 5 29 9 31 5 35 16 23 5 255 27 12 n with metal bellows actuator 550 18 5 2 24 605 Actuator A 62 cm 5to 10 bar 10 to 22 bar Set point ranges Height H 550 605 Actuator Height H 535 62 cm 590 Actuator 33 cm 20 to 28 bar Height H Actuator 535 590 33 Weight for version with metal bellows actuator 33cm Based on cost 16 5 17 9 18 235 25 5 29 62 iron approx kg 20 9 1 10 for other m2. Max permissible temperature See pressure temperature diagram in gt T 2500 Valve plug Metal seal max 350 PTFE soft seal max 220 EPDM or FPM soft seal max 150 C NBR soft sealing max 80 Leakage class according to IEC 60534 4 Metal seal leakage class 0 05 of Ky coefficient Soft seal leakage class IV 0 01 of Kys coefficient Compliance CE Hill Diaphragm actuator Set point ranges Type 2413 0 05 to 0 25 0 1 to 0 6 bar 0 2 to 1 2 bar 0 8 to 2 5 bar 2 2 to 5 bar 4 5 to 10 bar 8 to 16 bar Max permissible temperature Metal bellows actuator Actuator area Gases 350 C however 80 C at the actuator Liquids 150 C with compensation chamber max 350 Steam with compensation chamber max 350 Type 2413 33 cm 62 cm Set point ranges 2 to 6 bar 5 to 10 bar 10 to 22 bar 20 to 28 bar Set point spring 1 With oxygen max 60 2 Set point spring 4400 3 Version with actuator with two diaphragms 1 to 2 5 bar 18 EB 2517 EN Max permissible pressure at actuator Set point range Actuator with rolling diaphragm 0 05 to 0 25 bar 0 1 to 0 6 bar 0 2 to 1 2 bar 0 8 to 2 5 bar 2 to 5 bar Technical data 4 5 to 10 bar 8 to 16 bar Max perm p ressure above the set point adjusted at the actuator 0 6 bar 0 6 bar Set point rang
3. 14 Replacing the operating diaphragm 14 un er ee an 16 Dimensl on energie 17 Customer InguInes 18 Tr 19 2517 3 General safety instructions u General safety instructions The regulator is to 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 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 quest To ensure appropriate use only use the regulator in applications where the operating pressure and temperatures do not exceed the specifications use
4. 4 Installation 4 1 Assembly See 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 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 Bellows Set point adjuster Set point springs Bracket 1 Pillar 2 Nuts for pillars 3 Tapped holes 9 Fastening nuts 10 Diaphragm actuator 11 Actuator stem 12 Operating diaphragm 12 1 Operating bellows 13 Diaphragm plate 14 Nut 15 Nuts and bolts 16 Control line connection for steam including screw joint with restriction 17 Contro
5. 9 mm 97 137 mm 1 7 89 111 mm 162 2 1 99 x 126 187 0 2 1 2 0 45 1 mm 86 x 118 mm 0 70 83 103 147 1 0 bar x 95 mm 120 mm x 177 mm 0 1 to 0 6 bar 0 23 bar 1 mm x 118 mm 0 35 bar x 83 mm 147 mm 0 48 95 mm x 177 mm 0 05 to 0 25 bar 0 10 bar 0 15 bar x 70 mm x 112 mm x 136 mm 0 20 bar 5 3 Decommissioning x 159 mm Close first the shut off valve on the upstream side of the valve and then on the down stream side of the valve EB 2517 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 malfunctions Details on faults and how to remedy them can be found in Table 3 on page 14 WARNING 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 ambie
6. 89 Excess pressure valve Downstream pressure gauge 160 80 40 cm 1190 8788 Fig 3 Example of installation with steam EB 2517 EN Shut off valve Installation 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 tap ping point to the 3 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 be in stalled with a downward slope In this case use 38 pipe with screw fittings If the control line connection is located below the middle of the valve inlet flange arrange the compensation chamber at the same level as the inlet flange In this case use a pipe which is at least V2 in size for the control line from the tapping point to the compensa tion 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 upstream pressure tapping point The ad ditional pressure of the condensate head must be compensated for by adjusting the set point 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
7. Self operated Pressure Regulators Type 41 73 Universal Excess Pressure Valve Type 41 73 Excess Pressure Valve Mounting and Operating Instructions EB 2517 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 Note WARNING Additional information Hazardous situations which if not avoided could result in death or seri ous in SE Mp jury P R ecommended action 2 EB 2517 EN 10 Contents General safety instructions eeueessnsssonsensnsenonsennnsennnsnnnnsnnsnssnnnsnnnnsnnnnnsnnnnssnnnnnne 4 Process medium and scope of application eese sss 5 Transporlalion and 5 Design and principle of operation eese eere eese rennen eere 5 er eier 6 PEN ee ENNA E A ERST 6 POURING BOSI ON ee ae ee ee 8 Control line compensation chamber and needle valve 9 SEIS Her 10 STU e Ra 11 Pressure GOUDE ne ee see 11 Sp 12 gt 0 4 12 Adjusting the set OO IMF NT T IO 12 Decomimilssioif ipse NIAE 13 Cleaning and maintenance eee ee esee eene seen eere enero eset tn seen
8. aterials Version with actuator with two 2 5 16 2517 Customer inquiries Dimensional drawing Type 2417 Valve Type 41 73 Universal Excess Pressure Valve Type 2413 Type 2413 Diaphragm Actuator with Actuator metal bellows Actuator with two diaphragms 50 mm Fig 6 Dimensions 9 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 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 5 a strainer installed Installation drawing showing the exact location of the regulator and all the additionally installed components shut off valves pressure gauge etc EB 2517 EN 17 Technical data 10 Technical data All pressures in bar gauge Valve Nominal pressure Type 2417 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
9. d 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 2517 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 opens when the upstream pressure rises NOTICE The Type 41 73 Excess Pressure 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 before it is installed 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 supports 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 73 Excess Pressure Valve co
10. e Metal bellows actuator 2 to 6 bar 1 3 bar 5 to 10 bar 2 5 bar 5 bar 10 to 22 bar 10 bar 10 bar 20 to 28 bar Max perm pressure above the set point adjusted at th e actuator 6 5 bar Note Conversion from chromate coating to iridescent passivation 6 5 bar 8 bar 2 bar 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 2517 EN 19 SAMSON AG MESS UND REGELTECHNIK Weism llerstraDe 60314 Frankfurt am Main Germany Phone 49 69 4009 0 Fax 49 69 4009 1507 samson samson de www samson de EB 2517 EN 2015 07 27 English
11. e 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 excess pressure valve in horizontal pipelines On installing the valve make sure the direction of flow corresponds with the ar row 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 automatic 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 after the entire plant has been completed The regulator must be in stalled free of stress If necessary support the pipe near the connecting flanges Standard mounting position For gases liquids and steam Alternative mounting position For Gases and liquids at medi um temperature up to 80 C Not for steam Not permissible 1 Installation in this position on request 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 upstream of the pressure tapping point Install a shut
12. l line installed on site control line kit available for tapping the pressure directly at the valve body see T 2595 18 Compensation chamber 19 Filler plug I EB 2517 EN Installation SR fg n Nii 9 LL g 7 Y f ZZ I RS NR AY 77 DIE 22 D N EEG SS NN 2 22377 IN KO il E UJ x E Actuator 2 gt lt ONG 4 Type 2413 Diaphragm ctuator for DN 65 to 100 t Type 41 73 Regulator DN 32 to 100 With balancing bellows 6 So a ji I 7 v Ay AU AU A AV AV AV 49 49 4 49 AV AV AV 4 4 4 4 AV AV AV AVA 7 LZ zZ ET al AP AV A8 AV AW A A9 A A A A AV AV A AV AV AV AV AV AV AV AV E foe NAS NSSS NASA SSS CO UCC Ut UO CU t t tb tt tpt trey 4 bra Functional diagram DN 15 to 50 Q B O N c o Q N N B O u o Q O LO u Q De 2 N N 3 9 o Q 5 em E _ 3 o 2 om lt gt E 2517 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 pipelin
13. line Upstream pressure fluctuates 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 2517 EN 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 Valve size Nominal pressure Perm differential pressure Perm temperature Body material ANSI version ANSI version Valve size 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 1 Effective area DIN ANSI Type Configuration ID Var ID ID number Max perm pressure above the set point adjusted at the actuator DIN ANSI Valve size DIN ANSI Set point range DIN ANSI Diaphragm material Fig 5 Nameplates EB 2517 EN 15 Dimensions 8 Dimensions Dimensions in mm and weights in kg Excess pressure valve Nominal size DN Type 41 73 32 40 50 Length L 200 Height H1
14. nd 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 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 and plug Restriction in the screw joint of the ac tuator dirty or too small Dirt in the control line 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 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 Clean the control
15. ng 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 EB 2517 EN Operation All pipes conveying the process medium must be completely drained and dry Air and condensate must be allowed to escape from the plant Allow time for the pipes and valves to heat up Regulation of liquids To start up the excess pressure valve open shut off valves slowly For temperatures above 150 first fill the compensation chamber with the pro cess medium 5 2 Adjusting the set point See Fig 1 on page 7 The required upstream 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 The following generally applies Turn clockwise tensioning the spring to increase the upstream pressure Turn counterclockwise relieving the tension on the
16. nsists of a Type 2417 Opening 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 excess pressure valve is used to maintain the pressure upstream of the valve to an adjust ed 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 2517 EN 5 Installation 5 1 The upstream pressure is transmit ted through the compensation chamber 18 and control line 17 to the operating dia phragm 12 where it is converted into a po sitioning force For actuator versions with a bellows the pressure is transmitted to the op erating 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 ad juster 6 Valves with Kys 4 and higher fea ture a balancing bellows 4 The upstream pressure acts on the outside of the bellows and the downstream pressure on the inside of the bellows As a result the forces pro duced by the upstream and downstream pressures acting on the plug are balanced Depending on the valve and actuator used the regulator can be upgraded to create a safety excess pressure valve
17. nt temperature Disconnect or shut off the control line to prevent the risk of moving regula parts As valves are not free of cavities remember that residual pro cess medium might still be contained in the valve EB 2517 EN 6 1 Cleaning and maintenance NOTICE 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 Replacing the operating di aphragm If the upstream pressure deviates consider ably from the set point check if the dia phragm is leaking and if necessary replace it 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 and 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 re sponse Slow control re sponse Possible reasons Insufficient pressure pulses on the op erating diaphragm Recommended action Clean the control line a
18. off valve in the bypass line 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 2517 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 upstream line at least one meter away from the valve inlet Weld the control line at the side in the mid dle of the pipe inclining at a ratio of ap proximately 1 10 up to the compensation chamber Installation Control line kit A control line kit for tap ping pressure directly at the valve body is available as an accessories part from SAM SON Compensation chamber see Table 1 A compensation chamber is required for liq uids above 150 C as well as for steam 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 Table 1 Assignment of compensation chamber 4 to regulator Type 2413 Actuator no Compensation chamber Shut off valve Upstream pressure gauge Actuator area A DN 15 to 50 640 cm 1190 8789 DN 65 to 250 1190 8790 Strainer Compensation chamber 320 cm 1190 8788 1190 87
19. spring to reduce the up stream pressure The pressure gauge located on the upstream 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 is reached 11 Operation Set point adjuster 6 Fig 4 Set point adjustment with dimension x Note Note that only a rough set point ad justment is performed by turning the set point adjustment until the distance x is reached The special properties of the process medium and plant are not taken into account in this case Check the pressure at the pressure gauge upstream of the regulator for a precise set point adjustment Table 2 lists the set points and their assigned distance x for the regulators and their vari ous set point ranges 12 Table 2 Set point adjustment Dimension x Set point range 8 to 16 bar Nominal size DN Assigned dimension x 15 to 25 32 to 50 65 to 100 10 bar x 89 mm x 111 mm x 153 mm 12 bar 97 mm x2122 mm x 170 mm 14 bar x 104 mm 133 mm 188 5 to 10 bar 5 9 bar 85 mm 105 mm 151 mm 7 3 bar x 93 mm x 117 mm x 172 mm x 101 mm 123 mm x 192 mm 83 mm 102 mm 146 mm 92 x 115 mm x 168 mm 100 mm 127 mm 190 mm 8 to 2 5 bar 1 2 bar x
20. upstream of the excess pressure 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 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 upstream side in front of the upstream pressure tapping point not between the tapping point and the valve EB 2517 EN 5 Operation 5 1 See Fig 1 on page 7 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 medi um Avoid pressure surges Slowly fill the plant Make sure that the pres sure rises simultaneously upstream and downstream of the regulator to avoid dam aging the balancing bellows 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 NOTICE The pressure at the actuator must not exceed the permissible pressure on lesti
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