Mounting and Operating Instructions EB 2552-1
Contents
1. 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 person nel 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 The declaration of conformity issued for a regula tor bearing the CE marking includes information on the applied conformity assessment procedure The declaration of conformity is available on request 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 valve by the process medium op erating pressure or by moving parts are to be2. Balanced by a bellows Nominal size DN 125 DN 150 DN 200 DN 250 Length L 400 mm 480 mm 600 mm 730 mm Height H 285 mm 315 mm 390 mm 390 mm Height H1 460 mm 590 mm 730 mm 730 mm Height H2 145 mm 175 mm 235 mm 260 mm Max height H3 2 lt 725 mm lt 825 mm 890 mm 890 mm Weight PN 16 with Type 50 ES Pilot Valve 75 kg 118 kg 260 kg 305 kg 1 410 96 for cast iron 1 0619 PN 25 and spheroidal graphite iron EN JS1049 PN 25 2 Depending on the pilot valve used Fig 5 Dimensions and weights Type 2422 Valve balanced by a bellows 20 EB 2552 1 EN Dimensions Type 2422 Valve DN 125 to 400 Balanced by diaphragm Nominal size DN 250 DN 300 DN 400 Length L 730mm 850mm 110mm Height H1 510mm 610mm Height H2 290 mm 390 mm Weight 16 with Type 50 ES Pilot Valve 1 10 for cast iron 1 0619 PN 25 and spheroidal graphite iron EN JS1049 PN 25 Fig 6 Dimensions and weights Type 2422 Valve balanced by a diaphragm EB 2552 1 EN 21 Customer service 10 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 c
3. EB 2552 1 EN Operation Slowly start up the plant and allow time for the pipes and valves to warm up Air and condensate must be allowed to escape from the plant Install steam trap e g SAMSON Type 13 E or air vent for steam operated systems e g SAMSON Type 3 at a suitable location 5 3 Set point adjustment See Fig 1 and Fig 2 Adjust the required downstream pressure set point while the plant consumer is open by turning the set point adjuster at the pilot valve 5 When the adjusted downstream pressure set point is reached the pilot valve closes caus ing the main valve to close as well Turn clockwise The set point pressure increases Turn counterclockwise The set point pressure is reduced The pressure gauge located on the down stream pressure side allows the adjusted set point to be monitored First set the minimum set point by turning the set point adjuster counterclockwise lt Wait until the pressure reducing valve starts to regulate before adjusting the set point by slowly turning the adjuster clockwise 11 Operation NOTICE Incorrectly adjusted set point or set point cannot be adjusted Malfunction Start by turning the set point adjust er by one turn at a time and wait until the downstream pressure reaches the set point As soon as the pressure re ducing valve starts to work you can adjust the set point by making larg er changes Wait several mi
4. acting on the plug surface causes the valve to open To ensure proper functioning the minimum differential pressure listed in Table 1 must be available as specified depending on the field of application The regulator version for steam is only ovail able with valves balanced by a bellows This version has a condensation chamber 10 al ready fitted in the control line The needle valve 9 is open and lead sealed Before start up fill the condensation chamber with water at the top filler opening Valve balanced by a bellows for steam 2 applications Minimum PP differential Valve balanced by a pressure Ap bellows for air water Valve balanced by a diaphragm EB 2552 1 EN Design and principle of operation Type 2333 Pressure Reducing Valve Type 2422 Valve balanced by a bellows DN 125 to 250 Type 2422 as main valve balanced by a bellows NE 55554 Ake CL A m aN f PCA Lower section with bellows Version suitable for steam Version suitable for liquids and gases Globe valve main valve Valve seat Plug with plug stem Positioning spring Balancing bellows Pilot valve Venturi nozzle for gases and liquids GR WWD Strainer Fig 1 EB 2552 1 EN Fixed restriction version for steam Needle valve version for steam Condensation chamber only for steam or medium temperatures above 1
5. prevented by taking appropri ate precautions Proper transport storage installation operation and maintenance are as sumed EB 2552 1 EN Process medium and scope of application 2 Process medium and scope of application Pressure regulators for set points from 2 to 28 bar Valve nominal sizes DN 125 to 400 Nom inal pressure PN 16 to 40 Suitable for liquids gases and vapors up to 350 C The differential pressure across the regulator is used as auxiliary energy to operate the valve To open the regulator this pressure must be at least as high as the minimum differential pres sure specified in Table 1 The mounted pilot valve pressure reducing valve determines the function of the regulator WARNING Risk of uncontrolled excess pressure in the plant Risk of bursting 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 temperature outside the ambient temperature range Do not remove the protective caps from the valve ports until immediately before installing the valve into the pipeline When regulators are too heavy to be lifted by hand fasten the lifting sling at a suitable place on the valve body WARNING N Do not attach lifting slings or supports to mounting parts such as control line pilot valve e
6. valve is installed is clogged up Clean strainer The required minimum differ ential pressure to operate the regulator is not available Raise upstream pressure or re duce downstream pressure Set point range of the pilot valve is too low Convert or replace pilot valve Main valve seized up Clean main valve Install a shut off valve instead of the pilot valve If the main valve does not open when the shut off valve is opened the main valve has caused the malfunction Pilot valve seized up Needle valve installed be tween fixed restriction and main valve is jammed or closed Clean pilot valve Clean inter nal control line used to tap the downstream pressure Clean the needle valve Check setting open Install a shut off valve instead of the pilot valve If the main valve does not open when the shut off valve is opened the main valve has caused the malfunction Main valve is sized to be too small Kys Cy Resize the valve Replace main valve Regulator s reaction is sluggish Strainer in the line in which the pilot valve is installed is clogged up Clean strainer Inside the pilot valve is clogged up impairing the flow through the valve Clean inside the pilot valve Needle valve installed be tween fixed restriction and main valve is jammed Clean the needle valve Check setting open The fixed restriction is clogged up Control line or
7. 10 to 22 20 to 28 Set point ranges in bar continuously adjust able at the pilot valve 1 Version with reduced Kys coefficient possible Same technical data as DN 150 2 lt 0 1 of Ky coefficient with metal seated plug 3 Version for steam up to 350 C 18 EB 2552 1 EN Technical data Type 2422 Valve Balanced by a diaphragm Suitable for liquids and gases Nominal size Nominal pressure PN 16 to 40 Kys coefficient 650 1 800 value 0 3 1 0 3 1 Minimum differential pressure 4 O Abar 0 5 AP nin Max permissible differential pressure Ap x 10 bar 10 bar Leakage class according to IEC 60534 4 lt 0 01 of Kys coefficient Type 50 ES 50 C 44 2 150 Type 44 0 B 44 1 150 C Type 2406 150 Type 41 23 150 Steam pressure reducing valve as special version on request Max permissble temperature de pending on the pilot valve Type 50 ES 2 5 to 6 4 to 10 Type 44 2 2 to 4 2 2 4 to 6 3 6 to 10 5 Type 44 0 44 1 B 2 to 6 4 to 10 8 to 20 bar Type 2405 2 to 5 4 5 to 10 Type 41 23 2 to 5 4 5 to 10 8 to 16 10 to 22 20 to 28 Set point ranges in bar continu ously adjustable at the pilot valve 1 Version with reduced Kys coefficient possible Same technical data as DN 150 EB 2552 1 EN 19 Dimensions 9 Dimensions Type 2422 Valve DN 125 to 250
8. 50 C Control pressure Upstream pressure Downstream pressure Functional diagram of valve balanced by a bellows Design and principle of operation Type 2333 Pressure Reducing Valve Type 2422 Valve balanced by a diaphragm DN 125 to 400 5 Pilot valve SII ZZ ZAZA Ze Type 2422 as main valve balanced by a diaphragm Valve body main valve Control pressure Valve seat p Upstream pressure Plug with plug stem p Downstream pressure Positioning spring Pilot valve Venturi nozzle Strainer 1 2 3 5 6 7 1 1 Balancing diaphragm Fig 2 Functional diagram of valve balanced by a diaphragm 8 EB 2552 1 EN 4 Installation See Fig 3 Select the installation location making sure that the regulator is installed at a distance of at least six times the nominal size DN away from pipe fittings instruments or flow diver sions They can change the flow conditions which may lead to an instable control pro cess especially in applications with gases air or steam Contact SAMSON to obtain the TV SK 17041 documentation which contains more details on installation requirements 4 1 Notes on installation Install the ready assembled regulator in hori zontal pipelines Flush and clean the pipeline thorough ly before installing the regulator Other wise impurities in the pipeline may im pair the proper functioning of the valve above all the tight shut off D
9. Self operated Pressure Regulators Type 2333 Pressure Reducing Valve with pilot valve Type 2333 Pressure Reducing Valve Mounting and Operating Instructions EB 2552 1 EN Edition November 2014 Definition of signal words DANGER NOTICE Hazardous situations which if not Property damage message or mal avoided will result in death or seri function ous Injury _ aa Note WARNING Additional information Hazardous situations which if not avoided could result in death or se rious inj Aye p jury P R ecommended action 2 EB 2552 1 EN 10 Contents General safety instructions cssccsssscsssscssscssscccssscssssssssccsscssssscsensessesseees 4 Process medium and scope of application eese 5 Transporlalion and SIOFIS 5 Design and principle of operation ces eeee eere eene eren eene nennen 6 ae ea ee TE 9 Noles es 9 EE e N TOT 10 Shutoff To I II REA ERR 10 Pressure GAUSS MEET 10 elim E 11 IC OT TT OR 11 I ADB ee ol 11 SE a UE 11 BI eoa Sn OS 12 Maintenance unserem 13 17 Tedna 18 Dimensions e ee 20 Customer Service e n 22 EB 2552 1 EN 3 General safety instructions General safety instructions
10. Venturi noz zle blocked EB 2552 1 EN Clean fixed restriction Clean parts Improve steam conditioning if nec essary 15 Maintenance Troubleshooting continued Malfunction Possible reasons Recommended action Comments Control loop hunts Kys Cy of pilot valve too large after valve has been re placed Install pilot valve with suitable Kys C coefficient The flow conditions in the plant at the location where the regulator is installed are not suitable for the regulator Pipe reducers instruments and diversions can change the flow conditions which may lead to an instable control process especially in applica tions with gases air or steam Refer to the SAMSON docu ment TV SK 17041 for mini mum distances If this is the case send a sketch of the plant to SAMSON for a thor ough analysis 16 Kys C of main valve too large Occasional vibrational excita tion originating from the plant Resize the valve Replace main valve or convert it to another coefficient Contact SAMSON Possibly change the natural fre quency e g over the needle valve 9 when there is resonance in the plant EB 2552 1 EN 7 Nameplate Nameplate of main valve AMSON DIN version ANSI version Valve Valve type Model number Model number index Order number or date Kys coefficient Nominal size Nominal pressure Perm differential pressur
11. ancing bellows dia phragm defective Medium leaks from the actuator Pilot valve seized up when the consumer is open or at maximum load Replace the defective compo nent Clean the pilot valve Apply grease to plug stem guides if necessary Replace defec tive parts Install a shut off valve instead of the pilot valve If the main valve closes when the shut off valve is closed the pilot valve has caused the malfunction Main valve seized up Clean main valve Install a shut off valve instead of the pilot valve If the main valve does not close when the shut off valve is closed the main valve has caused the malfunction Balancing bellows dia phragm of the main valve defective Replace bellows diaphragm Install a shut off valve instead of the pilot valve If the main valve does not close when the shut off valve is closed the main valve has caused the malfunction Par ticularly in steam applications steam hammering can dam age the bellows Therefore make sure that no water or conden sate is present in the pipeline be fore start up In steam applications plant started up too quickly Fill condensation chambers with water Slowly start up the plant EB 2552 1 EN Troubleshooting continued Malfunction Possible reasons Recommended action Maintenance Comments The required downstream pressure is not reached Strainer in the line in which the pilot
12. atalogs 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 Order and model number Order number or date Upstream and downstream pressure Temperature and process medium Min and max flow rate in m h ls a strainer installed Installation drawing showing the exact location of the regulator and all the additionally installed components shut off valves pressure gauge etc Photo of the installed regulator if possible 22 EB 2552 1 EN 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 2552 1 EN 2014 11 25 English Conversion from chromate coating to iridescent passivation D 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 For further information go to www samson de chrome en html
13. by a sleeve to allow it to move The spring loaded actuator stem must not touch the insulation Installation Thermal insulation Note Do not insulate the pilot valve as well in applications with medium tempera tures above 80 C Pressure testing of the plant The pressure must not exceed the maximum permissible pressure of the regulator and plant on test ing the pressure of the plant when the regula tor is already installed An excessive test pres sure can damage the balancing bellows or di aphragm If necessary remove the regulator from the pipeline or isolate the regulator in the pipeline and install a bypass 4 2 Strainers Install the strainer e g SAMSON Type 1 Type 2 upstream of the pressure reducing valve The direction of flow must correspond to the arrow on the body Shut off valve Upstream pressure gauge Strainer Downstream pressure gauge Shut off valve Venturi nozzle Strainer in the pilot valve line The filter element must be installed to hang downwards or sideways for appli cations with steam Tip pos Remember to leave enough space to remove the filler element 4 3 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 peri ods of time 4 4 Pressure gauges Install a pressure gauge both up
14. e in bar Perm temperature in C Body material For ANSI version 5 8 9 10 11 12 Valve size Perm differential pressure in psi Perm temperature in F Body material Cy coefficient Kys x 1 17 ANSI Class pressure rating Fig 4 Nameplate of Type 2333 Pressure Reducing Valve EB 2552 1 EN Nameplate 17 Technical data 8 Technical data Table 3 Technical data All pressures in bar gauge Type 2422 Valve Balanced a bellows Suitable for liquids gases or vapors Nominal size DN 125 DN 150 DN 200 DN 250 Nominal pressure PN 16 to 40 Kys coefficient 200 360 520 6201 Kysl with flow divider St I 150 270 400 7 500 1 with flow divider St Ill 100 180 2601 3101 Vale 0 35 0 3 0 3 0 3 Minimum differential pressure For vapors 1 9 bar 2 0 bar 1 4 bar 1 1 4 bar For gases and liquids 1 0 bar 1 0 bar 0 7 bar 1 0 7 bar Max permissible differential pressure 16 bar 12 bar 10 bar Leakage class according to IEC 60534 4 lt 0 05 9 of Kys coefficient 2 Max permissble temperature depending on the pilot valve Type 50 ES 50 C Type 44 2 150 C Type 44 0 B 200 C 44 1 B 150 Type 41 23 150 C 3 Type 2405 150 C Type 50 ES 2 5 to 6 4 to 10 Type 44 2 2 to 4 2 2 4 to 6 3 6 to 10 5 Type 44 0 B 44 1 B 2 to 6 4 to 10 8 to 20 Type 2405 2 to 5 4 5 to 10 Type 41 23 2 to 5 4 5 to 10 8 to 16
15. irection of flow must match the direc tion indicated by the arrow on the body Install the regulator free of stress If nec essary support the pipeline near to the connecting flanges Do not attach sup ports directly to the valve or actuator Install a strainer upstream of the regu lator Protect the regulator from icing up when controlling media that can freeze If nec essary depressurize and drain the reg ulator and remove it from the pipeline while the plant is shut down EB 2552 1 EN Installation Note The side on which the operating ele ments hook up of the pilot valve are located varies depending on whether a valve balanced by a bellows or a di aphragm is used D Mounting position Valve balanced by a bellows Bellows including housing suspended downward Valve balanced by a diaphragm Balancing diaphragm diaphragm sec tion pointing upward Insulation To insulate cold systems we ommend first filling the plant and carefully rinsing it see section 5 1 The regulator must not be insulated until the set point is adjusted Start up the plant and adjust the set point Shut down the plant again and let it warm up until the condensation water has dried off Afterwards insulate the regulator and pipes conveying the process medi um using insulation material with a wa ter vapor barrier If the pilot valve has a spring it must must be protected
16. nutes un til the pressure conditions have stabi lized and check the set point Correct the set point if necessary After start up and set point adjustment avoid fast changes in pressure 5 4 Decommissioning Depressurize the plant Close the shut off valves starting from the flow side high pres sure line 12 EB 2552 1 EN 6 Maintenance 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 pos sible malfunctions WARNING Performing work on pressurized or hot plant sections Hot process medium can escape un controlled on dismantling the regula tor Risk of scalding Allow the regulator to cool down be fore depressurizing and draining it to remove it from the pipeline Details on faults and how to remedy them can be found in Table 2 The listed examples of malfunctions are caused by mechanical faults in the main valve or pilot valve as well as incorrect regulator sizing In the simplest case the functioning can be re stored following the recommended action To repair the pilot valve read the operating in structions for the corresponding regulator pi lot valve As in many cases special tools are required we advise you to contact SAMSON after sales service to find out how to proceed to repair the regulat
17. or or replace a component see section 10 Exceptional operating and installation condi tions can lead to changed situations that may EB 2552 1 EN Maintenance affect the control response and lead to mal functions In such cases check the installa tion conditions process medium temperature and pressure conditions A thorough analy sis may often require the on site assistance of SAMSON after sales service The table is not intended to be exhaustive as there are diverse reasons for malfunctions 13 Maintenance Table 2 Troubleshooting Malfunction Possible reasons Recommended action Comments Malfunction only occurs when the consumer is clos Downstream pressure is much higher than the adjusted set point Pilot valve Leakage between seat and plug ed or during low load Remove valve from the pipeline and clean seat and plug Re new plug if necessary Otherwise return regulator to SAMSON for repair Install a shut off valve instead of the pilot valve If the main valve closes when the shut off valve is closed the pilot valve has caused the malfunction Main valve Leakage tween seat and plug Remove valve from the pipeline and clean seat and plug Re new plug if necessary Otherwise return regulator to SAMSON for repair Malfunction occurs Downstream pressure is much higher than the adjusted set point 14 The pilot valve does not func tion Bal
18. stream and downstream of the regulator to monitor the pressures prevailing in the plant Type 2422 as 5 main valve Type 2333 Pressure Reducing Valve 9 Pilot valve Fig 3 Installation example for Type 2333 Pressure Reducing Valve 10 EB 2552 1 EN 5 Operation See Fig 1 and Fig 2 5 1 Start up First start up the regulator after mounting all parts e g valve and control line Open con trol line with needle valve and check to ensure it is connected correctly Rinsing the plant After filling the plant first completely open the consumer and adjust the regulators to achieve the maximum flow rate Rinse out the pipeline at full flow rate for sev eral minutes Check the installed strainer e g by measuring the pressure drop Clean the strainer if necessary Slowly fill the plant Make sure that the pressure rises simultaneously upstream and downstream of the regulator to avoid damaging the balancing bellows diaphragm Open all the valves on the consum er side Slowly open the shut off valves starting on the flow pipe side in small steps waiting a few minutes inbetween 5 2 Steam applications Observe the following points for applications with steam Before start up all pipes conveying the process medium must be completely drained and dry to prevent steam ham mering Before start up fill the condensation chamber 10 with water also at the pi lot valve if necessary
19. tc The valve can fall or mounting parts may be damaged Securely fasten slings or supports to the valve body and secure against slipping EB 2552 1 EN 5 Design and principle of operation 3 Design and principle of op eration See Fig 1 and Fig 2 The medium flows through the globe valve 1 in the direction indicated by the arrow The position of the plug determines the flow rate across the area released between plug 3 and valve seat 2 The travel position of the pilot valve 5 determines the pressure condi tions across the valve The forces created by the upstream pressure p acting on the plug surface and by the con trol pressure ps acting on the balancing bel lows 4 or balancing diaphragm 11 and the force of positioning spring 3 1 are com pared In the Type 2333 Pressure Reducing Valve a rise in downstream pressure p causes the pi lot valve to close The control pressure in creases and the plug of the main valve starts to close When the pilot valve is closed p the pressure reducing valve main valve is also completely closed Table 1 Minimum differential pressure Nominal size Together with the pilot valve the fixed restric tion 8 or the Venturi nozzle 6 create the control pressure p IF the downstream pressure falls again be low the set point the pilot valve opens The control pressure falls as a result The force resulting from the upstream pressure p
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