Samson 2412 Series Mounting And Operating Instructions
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Samson 2412 Series Mounting And Operating Instructions

Type 41-23 universal pressure reducing valve, self-operated pressure regulators.
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EB 2512 EN
Translation of original instructions
Type 41-23 Universal Pressure Reducing Valve
Self-operated Pressure Regulators
Edition April 2019

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Summary of Contents for Samson 2412 Series

  • Page 1 EB 2512 EN Translation of original instructions Type 41-23 Universal Pressure Reducing Valve Self-operated Pressure Regulators Edition April 2019...
  • Page 2 Î For the safe and proper use of these instructions, read them carefully and keep them for later reference. Î If you have any questions about these instructions, contact SAMSON‘s After-sales Service Department (aftersalesservice@samson.de). The mounting and operating instructions for the devices are included in the scope of delivery.

  • Page 3: Table Of Contents

    Contents Safety instructions and safety measures ............5 Notes on possible severe personal injury ............8 Notes on possible personal injury ..............8 Warning markings on the regulator ...............11 Markings on the device ................12 Nameplates ....................12 Locations of the nameplate ................13 Warnings ....................13 Material number ..................13 2.4.1 Type 2412 Valve ..................13...
  • Page 4 Contents Start-up and operation ................32 Start-up .......................32 6.1.1 Installing the regulator ..................33 6.1.2 Pipeline flushing ...................34 6.1.3 Pressure test ....................34 Operation ....................35 Starting up the plant ..................35 6.3.1 Regulation of liquids ..................36 6.3.2 Regulation of steam ..................36 Adjusting the set point ..................36 Maintenance ....................37 Replacing the actuator ..................39 Replacing the set point springs ..............40...

  • Page 5: Safety Instructions And Safety Measures

    In case operators intend to use the regulators in other applications or conditions than specified, contact SAMSON. SAMSON does not assume any liability for damage resulting from the failure to use the de- vice for its intended purpose or for damage caused by external forces or any other external factors.
  • Page 6 Î Wear hearing protection when working near the regulator. Î Check with the plant operator for details on further protective equipment. Revisions and other modifications Revisions, conversions or other modifications of the product are not authorized by SAMSON. They are performed at the user's own risk and may lead to safety hazards, for example. Fur- thermore, the product may no longer meet the requirements for its intended use.
  • Page 7 Safety instructions and safety measures Responsibilities of operating personnel Operating personnel must read and understand these mounting and operating instructions as well as the referenced documents and observe the specified hazard statements, warnings and caution notes. Furthermore, the operating personnel must be familiar with the applicable health, safety and accident prevention regulations and comply with them. Referenced standards and regulations The regulators comply with the requirements of the European Pressure Equipment Directive 2014/68/EU. Regulators with a CE marking have an EU declaration of conformity, which...

  • Page 8: Notes On Possible Severe Personal Injury

    Î Before performing any work on the regulator, depressurize the plant. Disconnect or shut off the external control line. Damage to health relating to the REACH regulation. If a SAMSON device contains a substance which is listed as being a substance of very high concern on the candidate list of the REACH regulation, this circumstance is indi- cated on the SAMSON delivery note. Î Information on safe use of the part affected, see u http://www.samson.de/reach- en.html.
  • Page 9 Safety instructions and safety measures 1.2 Notes on possible personal injury WARNING Risk of personal injury due to residual process medium in the regulator. While working on the regulator, residual process medium can escape and, depending on its properties, may lead to personal injury, e.g. (chemical) burns. Î...
  • Page 10 The lubricants to be used depend on the regulator material. Unsuitable lubricants may corrode and damage the surface. Î Only use lubricants approved by SAMSON.When in doubt, consult SAMSON. Risk of leakage and regulator damage due to excessively high or low tightening torques.

  • Page 11: Warning Markings On The Regulator

    Î Prevent the formation of ice by taking appropriate precautions (e.g. enclosure, trace heater etc.). The plant operator is responsible for selecting and implementing appropriate precautions. See section 5.4.3. Note SAMSON's After-sales Service department can support you concerning lubricant, tighten- ing torques and tools approved by SAMSON. 1.4 Warning markings on the regulator Warning...

  • Page 12: Markings On The Device

    Markings on the device 2 Markings on the device Several nameplates are affixed to the device. The regulator nameplate indicates the device number of the final assembly of regulator components. The individual regulator components have their own nameplates (see Fig. 1) as well. 2.1 Nameplates Valve nameplate DIN version ANSI version ANSI version · DIN version Valve type Nominal pressure Model number with index Perm. differential pressure Set point range or spring Configuration ID range 10 Perm.

  • Page 13: Locations Of The Nameplate

    Markings on the device 2.2 Locations of the nameplate 2.4 Material number 2.4.1 Type 2412 Valve See the nameplate (12 for DIN version or 10 for ANSI version, body material). For more details on the nameplate, see section 2.1. Location of the 2.4.2 Type 2413 Actuator nameplate on the regulator components Specifying the configuration ID, you can con-...

  • Page 14: Design And Principle Of Operation

    Design and principle of operation 3 Design and principle of oper- Depending on the valve and actuator used, the regulator can be upgraded to create a ation pressure reducing valve for low flow rates, a Î Refer to Fig. 3 steam pressure reducing valve or a pressure reducing valve with increased safety (actua- The Type 41-23 Pressure Reducing Valve tor with two diaphragms).
  • Page 15 Design and principle of operation Type 2412 Valve Bellows actuator for DN 15 to 50 12.1 Bellows actuator for DN 65 to 100 Type 2413 Diaphragm Actuator Type 2413 Bellows Actuator for 2 to 6, 5 to 10, 10 to 22 and 20 to 28 bar Fig. 3: Functional diagram for regulators, DN 32 to 100 with balancing bellows EB 2512 EN...

  • Page 16: Technical Data

    Design and principle of operation 3.1 Technical data Noise emission SAMSON is unable to make general state- The valve and actuator nameplates provide ments about noise emission as it depends on information on the valve and actuator ver- the regulator version, plant facilities, process sions (see section 2.1).
  • Page 17 Design and principle of operation Table 1: Technical data · All pressures in bar (gauge) Valve Type 2412 Valve size DN 15 to 50 DN 65 to 80 DN 100 Nominal pressure PN 16, 25 or 40 Max. permissible differential 25 bar 20 bar 16 bar pressure ∆p Valve Max. u T 2500 ∙ Pressure-temperature diagram permissible Metal seal: 350 °C · PTFE soft seal: 220 °C Valve plug temperature EPDM or FKM soft seal: 150 °C ·...
  • Page 18 Design and principle of operation Table 2: Max. permissible pressure at actuator Max. perm. pressure above the set point adjusted at the Set point ranges actuator 0.05 to 0.25 bar · 0.1 to 0.6 bar 0.6 bar 0.2 to 1.2 bar 1.3 bar 0.8 to 2.5 bar 2.5 bar 2 to 5 bar 5 bar 4.5 to 10 bar · 8 to 16 bar 10 bar 2 to 6 bar · 5 to 10 bar 6.5 bar 10 to 22 bar 8 bar 20 to 28 bar 2 bar Note The maximum permissible pressure at the actuator depends on the currently adjusted set...
  • Page 19 Design and principle of operation Table 3: K coefficients and x values · Terms for noise level calculation according to VDMA 24422 (edition 1.89) Valve size  · Standard version  1) 0.45 0.35  · Special version 1.0 · 4.0 4.0 · 8.0  1)  2) 0.45  · With flow divider  1) ≤4: valve without balancing bellows Max. permissible ∆p: 25 bar Table 4: Materials · Material numbers according to DIN EN Valve Type 2412 Nominal pressure...
  • Page 20 Design and principle of operation Table 5: Dimensions in mm and weights in kg Pressure reducing valve Type 41-23 Valve size DN 15 DN 20 DN 25 DN 32 DN 40 DN 50 DN 65 DN 80 DN 100 Length L Height H1 Forged steel – – – – Height H2 Other materials Standard version with Type 2413 Diaphragm Actuator Height H  3)
  • Page 21 Design and principle of operation Table 5: Dimensions in mm and weights in kg Pressure reducing valve Type 41-23 Valve size DN 15 DN 20 DN 25 DN 32 DN 40 DN 50 DN 65 DN 80 DN 100 0.05 to 22.5 23.5 29.5 31.5 0.6 bar Weight, based on 0.2 to cast iron ...
  • Page 22 Design and principle of operation Dimensional drawings ØD ØD Type 41-23 with diaphragm actuator Type 41-23 with bellows actuator Fig. 4: Dimensions EB 2512 EN...

  • Page 23: Measures For Preparation Before Installation

    2. Check the shipment for transportation DANGER damage. Report any damage to Hazard due to suspended loads falling. SAMSON and the forwarding agent Stay clear of suspended or moving loads. (refer to delivery note). 4.1 Unpacking WARNING Risk of lifting equipment tipping and risk of...

  • Page 24: Transport

    Measures for preparation before installation 4.2.1 Transport − Make sure that the axis of the pipeline is always horizontal during lifting and the The regulator can be transported using lifting axis of the plug stem is always vertical. equipment (e.g. crane or forklift). Lifting Î Leave the regulator in its transport con- tainer or on the pallet to transport it.

  • Page 25: Storage

    − Observe storage instructions. − Avoid long storage times. − Protect the regulator against moisture − Contact SAMSON in case of different stor- and dirt. Store it at a relative humidity of age conditions or long storage periods. less than 75 %. In damp spaces, prevent condensation.

  • Page 26: Assembly

    Any impurities carried along by the process medium may impair the proper functioning of the regulator. We recommend installing a strainer (e.g. SAMSON Type 2 NI) upstream of the pressure reducing valve. 5 Assembly Î Check to make sure that the type desig-...

  • Page 27: Checking The Installation Conditions

    Assembly 5.2 Checking the installation NOTICE conditions Do not attach supports directly to the valve or actuator. 5.2.1 Mounting position Î Install the actuator housing with the set Note point springs suspended downward in Do not install any instruments (e.g. tempera- horizontal pipelines (see section Fig. 6).

  • Page 28: Pipeline Routing

    A control line kit for tapping pressure at the Table 6). Contact SAMSON if the valve valve body is available as an accessory part conditions or states of the medium pro- from SAMSON. cess deviate. 5.3.3 Compensation chamber Î Install the regulator free of stress and with the least amount of vibrations as Î...

  • Page 29: Needle Valve

    (16) in addition to the standard tion chamber. SAMSON screw joint with restriction. If the control line is connected above the middle of the valve inlet flange, install the compensation chamber at the same level as the upstream pressure tapping point.
  • Page 30 Assembly Correct! Connection at the top – incorrect position Connection at the side – optimal Connection at the bottom – incorrect position Fig. 7: Control line connection, depending on how the pipeline is routed Control line connection below the Control line connection in pipeline: middle of the flange: Min.

  • Page 31: Additional Fittings

    For used for longer periods of time. example, the SAMSON Type 2 NI Strainer is suitable (u T 1015). − The bypass ensures that the plant does not need to be shut down for service and The following points must be observed repair work on the regulator.

  • Page 32: Pressure Gauges

    Start-up and operation 5.4.4 Pressure gauges 6 Start-up and operation 6.1 Start-up − Install a pressure gauge (3 and 5) both upstream and downstream of the regula- tor to monitor the pressures prevailing in DANGER the plant. Risk of personal injury due to process me- dium escaping under pressure.

  • Page 33: Installing The Regulator

    Start-up and operation 6.1.1 Installing the regulator − Bellows actuator DN 65 to 100 Remove the crossbeam (8) from the Î Refer to Fig. 3 valve. 1. Close the shut-off valves upstream and Unscrew the pillars (8.1). downstream of the regulator while the Screw the pillars (8.1) into the threaded regulator is being installed.

  • Page 34: Pipeline Flushing

    Note after flushing the pipeline, proceed as de- The plant operator is responsible for per- scribed in Table 10. forming the pressure test. SAMSON's Af- ter-sales Service department can support you NOTICE to plan and perform a pressure test for your After removing the control line, seal the plant.

  • Page 35: Operation

    Start-up and operation 6.3 Starting up the plant − Make sure that the pressure rises simulta- neously upstream and downstream of the Î Refer to Fig. 3 regulator to avoid damaging the balanc- ing bellows. Î Start up the regulator after mounting all parts.

  • Page 36: Regulation Of Liquids

    Start-up and operation 6.3.1 Regulation of liquids 6.4 Adjusting the set point To start up the pressure reducing valve, open Î Refer to Fig. 9 shut-off valves slowly. Î The required downstream pressure is set Î For medium temperatures above 150 °C, by turning the set point adjuster (6) using first fill the compensation chamber with an open-end wrench: the process medium.

  • Page 37: Maintenance

    Start-up and operation 7 Maintenance Table 7: Set point adjustment · Dimension x Set point The regulator does not require any mainte- Valve size DN range nance. Nevertheless, it is subject to natural 8 to 16 bar 15 to 25 32 to 50 65 to 100 wear, particularly at the seat, plug and oper- 10 bar...
  • Page 38 SAMSON. down or heat up. − Wear protective clothing and safety gloves. Note The regulator was checked by SAMSON be- NOTICE fore it left the factory. Risk of regulator damage due to incorrect − Certain test results (seat leakage and leak servicing or repair.

  • Page 39: Replacing The Actuator

    − Bellows actuator DN 15 to 50 Note Insert the actuator stem (11) into the trav- SAMSON's After-sales Service department el stop cap with cotter pin (20). can support you concerning lubricant, Align actuator on the pillars (8.1) and tightening torques and tools approved by fasten it with the nuts (8.2).

  • Page 40: Replacing The Set Point Springs

    Observe the specified tightening torques. (8.1) and fasten with the nuts (8.2). Observe the tightening torques specified in section 7.5. Note 4. Mount the actuator (see section 7.1). SAMSON's After-sales Service department Observe the tightening torques specified can support you concerning lubricant, in section 7.5. tightening torques and tools approved by 5. Lock the cotter pin (20) on the travel stop SAMSON.

  • Page 41: Replacing The Seat And Plug

    See also the note on the cross- be replaced when it is defective. beam (8). Note Note SAMSON's After-sales Service department SAMSON's After-sales Service department can support you concerning lubricant, can support you concerning lubricant, tightening torques and tools approved by tightening torques and tools approved by SAMSON.

  • Page 42: Tightening Torques

    Maintenance Î Refer to Fig. 3 Mounting the operating diaphragm 1. Place a new operating diaphragm (12) Removing the operating diaphragm onto the diaphragm plate (13) (ensuring 1. Put the regulator out of operation (see the pressurized side is facing in the cor- section 9.1). rect direction) and tighten the diaphragm 2.

  • Page 43: Lubricants And Sealants

    Note Defective regulators can be returned to SAMSON's After-sales Service department SAMSON for repair. Proceed as follows to can support you concerning lubricants and return devices to SAMSON: sealants approved by SAMSON. 1. Put the regulator out of operation (see section 9.1).

  • Page 44: Ordering Spare Parts And Operating Supplies

    The malfunctions listed in Table 10 are caused by mechanical faults and incorrect Contact your nearest SAMSON subsidiary regulator sizing. In the simplest case, the or the SAMSON After-sales Service depart- functioning can be restored following the ment for information on spare parts, lubri- recommended action. Special tools may be cants and tools.
  • Page 45 Î Clean the control line and screw fittings. Î Remove foreign particles. Î Replace damaged parts. Foreign particles blocking the plug Î Contact SAMSON's After-sales Service department. Î Replace the damaged seat and plug. Seat and plug are worn or leak. Î Contact SAMSON's After-sales Service department.
  • Page 46 Regulator or K coefficient too install a different sized regulator. small Î Contact SAMSON's After-sales Service department. Î Reconnect the control line at another point. Pressure tapped at the wrong place Downstream pressure Î Do not connect the control line at pipe bends or (regulator with external control line).

  • Page 47: Decommissioning And Removal

    Decommissioning and removal 9 Decommissioning and 9.1 Decommissioning removal To decommission the regulator for service and repair work or disassembly, proceed as follows: DANGER Risk of bursting in pressure equipment. Î Refer to Fig. 8 Regulators and pipelines are pressure equip- 1. Close the shut-off valve (1) on the up- ment.

  • Page 48: Appendix

    Seat E-mail address Plug Body You can reach the After-sales Service De- Guide cap partment at aftersalesservice@samson.de. Guide (DN 32 to 100) Addresses of SAMSON AG and its subsid- 25, 26 Guide bushing/pipe (DN 15 to 25) iaries Flanged pipe Washer The addresses of SAMSON, its subsidiaries, Flange representatives and service facilities world-...
  • Page 49 Appendix 25/26 EB 2512 EN...

  • Page 50: Certificates

    Appendix Standard version (DN 15 to 25) 17.1 17.2 Version with soft-seated plug Version with flow divider Version (2012 onwards) Note Balancing screw There are no spare parts available Seat for the bellows actuators. The entire Plug actuator must be replaced when it is 17.1 Pre-stage of plug defective.
  • Page 51 EB 2512 EN...
  • Page 52 EB 2512 EN SAMSON AKTIENGESELLSCHAFT Weismüllerstraße 3 · 60314 Frankfurt am Main, Germany Phone: +49 69 4009-0 · Fax: +49 69 4009-1507 samson@samson.de · www.samson.de...

This manual is also suitable for:

2413 series41-23 series

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