Samson 45-9 Mounting And Operating Instructions
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Samson 45-9 Mounting And Operating Instructions

Samson 45-9 Mounting And Operating Instructions

Flow regulator
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EB 3128 EN
Translation of original instructions
Type 45-9 Flow Regulator
Self-operated Regulators
Edition April 2019

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Summary of Contents for Samson 45-9

  • Page 1 EB 3128 EN Translation of original instructions Type 45-9 Flow Regulator Self-operated 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 Notes on possible property damage ..............9 Markings on the device ................11 Nameplate ....................11 Nameplate position ..................11 Material number ..................11 Design and principle of operation ..............12 Technical data .....................14 3.1.1 Process medium and scope of application ............14...
  • Page 4 Contents Replacing the operating diaphragm ..............33 Lubricants and sealants ................34 7.5 Tightening torques and width across flats ............35 Accessories and tools ...................35 Preparation for return shipment ..............36 Ordering spare parts and operating supplies ..........36 Malfunctions ....................36 Decommissioning and removal ..............38 Decommissioning ..................39 Disposal ......................39 Appendix ....................39 10.1 After-sales service ..................39 10.2...

  • Page 5: Safety Instructions And Safety Measures

    In case operators intend to use the device 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 Observe safety measures for handling the device as well as fire prevention and explosion protection measures. Safety features The Type 45-9 Regulator does not have any special safety features. When relieved of pres- sure, the regulator is opened by the force of the set point springs. Responsibilities of the operator The operator is responsible for proper operation and compliance with the safety regulations. Operators are obliged to provide these mounting and operating instructions as well as the referenced documents to the operating personnel and to instruct them in proper operation.
  • 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. Devices with a CE marking have an EU declaration of conformity, which in-...

  • Page 8: Notes On Possible Severe Personal Injury

    Safety instructions and safety measures 1.1 Notes on possible severe personal injury DANGER Risk of bursting in pressure equipment. Regulators and pipelines are pressure equipment. Improper opening can lead to device components bursting. Î Observe the maximum permissible pressure for regulator and plant. Î...

  • Page 9: Notes On Possible Property Damage

    Î Allow components and pipelines to cool down or heat up. Î Wear protective clothing and safety gloves. 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 indicat- ed on the SAMSON delivery note.
  • 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: Markings On The Device

    Markings on the device 2 Markings on the device 2.1 Nameplate Configuration ID Model number Date of manufacture coefficient Pressure rating PN Differential pressure set point range in bar Type designation Flow rate set point range in m³/h Maximum permissible temperature in °C Max. permissible differential pressure ∆p in Fig. 1: Nameplate 2.2 Nameplate position 2.3 Material number The nameplate of all sizes is affixed to the...

  • Page 12: Design And Principle Of Operation

    11.1 Screw fitting a way that the differential pressure and the 15 Screws differential pressure created at the restriction are identical when the required maximum Fig. 3: Functional diagram of Type 45-9 flow rate exists. EB 3128 EN...
  • Page 13 Design and principle of operation PN 25 · DN 15 to 25 11.1 PN 25 · DN 32 to 50 11.1 Fig. 4: Functional diagram of Type 45-9 EB 3128 EN...

  • Page 14: Technical Data

     1) − Max. temperature for gases 80 °C · 150 °C  2) Note − Flow range, max. 14.1 m³/h The Type 45-9 Regulator is not a safety − Differential pressure across the restriction valve. If necessary, a suitable overpressure 0.2 bar ∆p   protection must be installed on site in the restriction −...
  • Page 15 Design and principle of operation Table 1: Technical data Valve size  2)  2)  2) coefficient 12.5 16.0 20.0  1)  1)  1) Flanged body – 12.5 20.0 25.0 value 0.55 0.45 Flanged body – 0.45 0.40 Pressure rating PN 16 · PN 25 PN 25 Max. permissible differential pressure 10 bar /20 bar...
  • Page 16 Design and principle of operation · The minimum required differential pressure Δp = Δp restriction Δp across the valve is calculated as follows: Δp Minimum differential pressure in bar across the valve Δp Differential pressure created at the restriction for measuring the flow rate restriction · Adjusted flow rate in m³/h Valve flow coefficient in m³/h Table 2: Materials Body Red brass CC499K (Rg 5) ·...
  • Page 17 Design and principle of operation Dimensional drawings ød ØD ØD Valve made of spheroidal graphite iron Red brass valve with welding ends (standard version) with flanges (DN 32, 40 and 50) With threaded ends With screw-on flanges (DN 15 to 25) Fig. 5: Dimensional drawings EB 3128 EN...
  • Page 18 Design and principle of operation Table 3: Regulator with connecting parts · Dimensions in mm and weights in kg Valve size DN 15 DN 20 DN 25 DN 32 DN 40 DN 50 With welding ends Length L1 Weight, approx. kg With threaded ends Length L2 Male thread A G 1½...

  • Page 19: Measures For Preparation

    − Observe storage instructions. − Avoid long storage times. − Contact SAMSON in case of different stor- Note age conditions or long storage periods. Do not remove the packaging until immedi- ately before installation.

  • Page 20: Mounting And Start-Up

    We recommend installing a − Do not place any objects on the device. strainer (e.g. SAMSON Type 1 NI) upstream of the flow regulator. Special storage instructions for elastomers Elastomer, e.g. diaphragm Î Check the regulator to make sure it is clean.

  • Page 21: Checking The Installation Conditions

    Flow pipe 1 Shut-off valve ∆p 2 Strainer 3 Pressure gauge 4 Motorized valve Return flow 5 Shut-off valve pipe 6 Type 45-9 7 Pressure gauge 8 Shut-off valve Fig. 6: Installation example · Type 45-9 in the return flow pipe EB 3128 EN...

  • Page 22: Additional Fittings

    Install a hand-operated shut-off valve both particles carried along by the medium. For upstream of the strainer and at the outlet of example, the SAMSON Type 1 NI Strainer is the return flow pipe. This allows the plant to suitable (u T 1010). be shut down for cleaning and maintenance,...

  • Page 23: Start-Up And Operation

    Start-up and operation 6 Start-up and operation 6.1.1 Installing the regulator Î See Fig. 3 and Fig. 4 1. Close the shut-off valves upstream and downstream of the regulator while the 6.1 Start-up regulator is being installed. 2. Remove the protective caps from the valve ports, if fitted, before installing the DANGER valve.

  • Page 24: Pipeline Flushing

    Note open the consumer The plant operator is responsible for 2. Adjust the maximum flow rate. Undo performing the pressure test. SAMSON's lock nut (8.2) and turn the set point After-sales Service department can support screw (8.3) counterclockwise () as far you to plan and perform a pressure test for as it will go.

  • Page 25: Operation

    Start-up and operation 6.2 Operation 6.4 Adjusting the set point The regulator is ready for use when mount- Î See Fig. 4 and Fig. 3 ing and start-up have been completed. NOTICE WARNING Set point adjustment is always based on a Risk of burn injuries due to hot or very cold closed restriction (1.2).
  • Page 26 Start-up and operation Different K coefficients are available for corresponds to one turn of the set point valve size DN 15 to provide several flow set screw). point ranges. Fig. 7: Type 45-9 Retighten the lock nut and screw the cap with scaled (8.6) back on after the required flow rate is cap for set point reached. adjustment Type 45-9 Flow Regulator in special version with external scaled cap (five scale divisions) for adjustment of the flow rate set point...
  • Page 27 Start-up and operation Table 5: Flow rate set points in m³/h for water Valve size DN DN 15 DN 20 DN 25 DN 32 DN 40 DN 50 16.0 20.0 coefficient 12.5  1)  1)  1) 20.0 25.0  2)  2) 0.12 0.01 Flow rate set 0.2 bar to 0.2 to 15 point range in 0.64...
  • Page 28 Start-up and operation One scale division <> One turn of the set point screw Turns of the set point screw or scale divisions DN 15 DN 25, DN 40, DN 50, 16/20 20/25 5 6 7 8 9 10 Flow rate – – – – DN 15, K 4.0: ∆p  = 0.3 bar...

  • Page 29: Maintenance

    Risk of burn injuries due to hot or cold com- ponents and pipelines. Depending on the process medium, regula- SAMSON's After-sales Service department tor components and pipelines may get very can support you in drawing up an inspection hot or cold and cause burn injuries.
  • Page 30 Maintenance NOTICE Note Risk of regulator damage due to the use of The regulator was checked by SAMSON be- unsuitable tools. fore it left the factory. Only use tools approved by SAMSON. − The product warranty becomes void if ser-...

  • Page 31: Replacing The Restriction

    Parts that are too loose may cause leakage. Observe the specified tightening torques. SW 19 NOTICE SAMSON order no. 1280-3001 Risk of damage to the facing of the seat and plug due to incorrect service or repair. Disassembly Always replace both the seat and plug.

  • Page 32: Replacing The Seat And Plug

    Maintenance 7.2 Replacing the seat and Note plug SAMSON's After-sales Service department can support you concerning lubricant, See Fig. 3 and Fig. 4. tightening torques and tools approved by SAMSON. NOTICE Risk of regulator damage due to excessively high or low tightening torques. Disassembly Observe the specified torques on tightening 1.

  • Page 33: Replacing The Operating Diaphragm

    (3) and screw in the plug nip- ple (3.5). Observe the tightening torques Note specified in section 7.5. SAMSON's After-sales Service department 4. Check the facings of the diaphragm case can support you concerning lubricant, (7) and the valve body (1) for dirt and tightening torques and tools approved by clean them, if necessary.

  • Page 34: Lubricants And Sealants

    7.4 Lubricants and sealants Assembly Note Note Before refastening the actuator, make sure SAMSON's After-sales Service department that the operating diaphragm has been in- can support you concerning lubricants and serted properly into the ring groove. sealants approved by SAMSON.

  • Page 35: Tightening Torques And Width Across Flats

    Maintenance 7.5 Tightening torques and width across flats Part Width across flats Valve size Tightening torque SW 30 DN 15 80 Nm SW 36 DN 20 95 Nm SW 46 DN 25 110 Nm Coupling nut (1.4) SW 59 DN 32 130 Nm SW 65 DN 40 160 Nm SW 82 DN 50 180 Nm – DN 15 to 25 45 Nm Seat (2) –...

  • Page 36: Preparation For Return Shipment

    Defective devices can be returned to sizing. In the simplest case, the functioning SAMSON for repair. Proceed as follows to can be restored following the recommended return devices to SAMSON: action. Special tools may be required for re- 1.
  • Page 37 Î Remove foreign particles. Foreign particles blocking the plug Î Replace damaged parts. Î Contact SAMSON's After-sales Service department. Flow rate ex- Î Replace the damaged seat and plug. ceeds adjusted Seat and plug are worn or leak.

  • Page 38: Decommissioning And Removal

    Decommissioning and removal 9 Decommissioning and remov- WARNING Risk of burn injuries due to hot or cold com- ponents and pipeline. Regulator components and the pipeline may DANGER become very hot or cold. Risk of burn inju- Risk of bursting in pressure equipment. ries.

  • Page 39: Decommissioning

    You can reach the After-sales Service De- 3. If necessary, allow the pipeline and reg- partment at aftersalesservice@samson.de. ulator to cool down or heat up. Addresses of SAMSON AG and its subsid- 4. Depressurize the plant. iaries 5. Completely drain the pipelines and regu- The addresses of SAMSON, its subsidiaries, lator.

  • Page 40: Spare Parts

    Appendix 10.2 Spare parts 186/187 186/187 30/160 7/207 31...34 65/66 134/135 155/255 190/191 Fig. 11: Spare parts for Type 45-9 EB 3128 EN...

  • Page 41: Certificates

    Appendix 10.3 Certificates Legend for Fig. 11 The EU declaration of conformity is provided Plug assembly on the next page. 180/5 O-ring Restriction assembly Scaled cap Stopper (DN 32 to 50) Body (DN 15 to 25) 31-34 Threaded seat (DN 15 to 25) Compression spring Compression spring Diaphragm case Hex screw Pipe Pipe Diaphragm case O-ring...
  • Page 42 Typ 2336, 2373, 2375, 44-1B, 44-2, 44-3, 44-4, 44-6B, 44-9, 45-1, 45-2, 45-3, 45-4, 45-6, (Erz.-Nr. 2720), 45-9, 47-4, 2488, 2489, (2730), 2405, 2406, 2421 (2811), 2412 (2812), 2417 (2817), 2422 (2814), 2423 (2823), 2423E (2823) die Konformität mit nachfolgender Anforderung/the conformity with the following requirement...
  • Page 43 2333 (Erz.-Nr./Model No. 2333), 2334 (2334), 2335 (2335), 2336, 2373, 2375, 44-0B, 44-1B, 44-2, 44-3, 44-6B, 44-7, 44-8, 45-1, 45-2, 45-3, 45-4, 45-5, 45-6, 2468, 2478 (2720), 45-9, 46-5, 46-6, 46-7, 46-9, 47-1, 47-4, 47-5, 47-9, 2487, 2488, 2489, 2491, 2494, 2495 (2730), 2405, 2406, 2421 (2811), 2392, 2412 (2812), 2114 (2814), 2417 (2817), 2422 (2814), 2423 (2823) die Konformität mit nachfolgender Anforderung/the conformity with the following requirement.
  • Page 44 EB 3128 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...

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