Samson 42-37 Mounting And Operating Instructions
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Samson 42-37 Mounting And Operating Instructions

Flow and differential pressure or pressure regulator
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EB 3017 EN
Translation of original instructions
Type 42-37 Flow and Differential Pressure Regulator
Type 42-39 Flow and Differential Pressure or Pressure Regulator
Self-operated Regulators
Edition August 2020

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Summary of Contents for Samson 42-37

  • Page 1 EB 3017 EN Translation of original instructions Type 42-37 Flow and Differential Pressure Regulator Type 42-39 Flow and Differential Pressure or Pressure Regulator Self-operated Regulators Edition August 2020...
  • Page 2 Note on this excerpt from the mounting and operating instructions This document contains an excerpt from the mounting and operating instructions named on the front cover. The structure of the overall document is based on the categories defined in VDI 2770 Directive and serves to classify the documentation. The contents of this part docu- ment apply to the category specified after the number of the mounting and operating instruc- tions (e.g.

  • Page 3: Table Of Contents

    Contents Safety instructions and measures ..............1-1 Notes on possible severe personal injury ............1-4 Notes on possible personal injury ..............1-5 Notes on possible property damage .............1-7 Markings on the device ................2-1 Nameplates ....................2-1 Location of the nameplates ................2-2 Material markings ..................2-2 2.3.1 Type 2423 Valve ..................2-2 2.3.2...
  • Page 4 Decommissioning ..................10-1 Removal ....................11-1 11.1 Removing the regulator from the pipeline ............11-1 11.2 Removing the actuator from the valve ............11-1 Repairs ....................12-1 12.1 Returning devices to SAMSON ..............12-1 Disposal ....................13-1 Certificates ....................14-1 Annex......................15-1 15.1 Tightening torques ..................15-1 15.2 Lubricant ....................15-1 15.3...

  • Page 5: Safety Instructions And 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 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 measures Warning against residual hazards To avoid personal injury or property damage, plant operators and operating personnel must prevent hazards that could be caused in the regulator by the process medium, the operating pressure or by moving parts by taking appropriate precautions. Plant operators and operat- ing personnel must observe all hazard statements, warning and caution notes in these mounting and operating instructions.

  • Page 8: Notes On Possible Severe Personal Injury

    Safety instructions and measures Referenced documentation The following documents apply in addition to these mounting and operating instructions: − Mounting and operating instructions for Type 2 N/NI Strainer e.g. u EB 1015 − Data sheets for e.g. Accessories · Differential pressure and flow regulators u T 3095 e.g.

  • Page 9: Notes On Possible Personal Injury

    Safety instructions and measures 1.2 Notes on possible personal injury WARNING Crush hazard arising from moving parts. The regulator contains moving parts (set point springs), which can injure hands or fin- gers if inserted into the regulator. Î Do not insert hands or fingers between the set point springs while the regulator is in operation.
  • Page 10 Î Wear protective clothing, safety gloves and eye protection. 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.

  • Page 11: Notes On Possible Property Damage

    The lubricants to be used depend on the regulator material. Unsuitable lubricants may corrode and damage surfaces. 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 12 Î Catch any liquids or gases that escape and may be harmful to the environment in a tank. Dispose of them in accordance with the applicable regulations. Note SAMSON's After-sales Service can support you concerning lubricant, tightening torques and tools approved by SAMSON. EB 3017 EN...

  • Page 13: Markings On The Device

    Markings on the device 2 Markings on the device Several nameplates are affixed to the device. The nameplates are used to identify the sepa- rate regulator components (see section 2.1). 2.1 Nameplates Nameplates of Type 2423 Valve DIN version ANSI version ANSI version · DIN version Pressure rating Valve type Set point range or spring...

  • Page 14: Location Of The Nameplates

    Markings on the device 2.2 Location of the nameplates 2.3 Material markings 2.3.1 Type 2423 Valve See the nameplate (11 for DIN/ANSI ver- sion, body material). For more details on the Location of the nameplate, see section 2.1. nameplate on the regulator components 2.3.2...

  • Page 15: Design And Principle Of Operation

    Design and principle of operation 3 Design and principle of oper- Type 42-37: The high pressure of ∆p acts on the bottom diaphragm chamber D over the ation control line (18). The high pressure of the Î See Fig. 3-1 to Fig. 3-3 flow rate upstream of the restriction (1.1) is...
  • Page 16 Design and principle of operation Type 2423 Valve balanced by a bellows Type 2427 12.1 Actuator 13.1 13.2 12.2 Fig. 3-1: Functional diagram of Type 42-37 Regulator, DN 15 to 250 with balancing bellows EB 3017 EN...
  • Page 17 Design and principle of operation Type 2423 Valve balanced by a bellows Type 2429 Actuator Fig. 3-2: Functional diagram of Type 42-39 Regulator, DN 15 to 250 with balancing bellows EB 3017 EN...
  • Page 18 Design and principle of operation Type 2423 Valve balanced by a diaphragm Type 2427 Actuator for Type 42-37 or Type 2429 Actuator for Type 42-39 Fig. 3-3: Functional diagram of Type 2423 Valve, DN 65 to 250 with balancing diaphragm Legend for Fig. 3-1 to Fig. 3-3 Valve body Spring...

  • Page 19: Additional Fittings

    Install a pressure gauge (3 and 6) at a suit- able point to monitor the pressures prevail- ing in the plant. Note The Type 42-37 and Type 42-39 Regulators Bypass and shut-off valves are not safety valves. If necessary, a suitable We recommend installing a shut-off valve (1...
  • Page 20 Differential pressure created at the restriction for measuring the flow rate in the regulator restriction · Adjusted flow rate in m³/h Valve flow coefficient in m³/h Fig. 3-4: Installation example: Type 42-37 and Type 42-39 installed in the flow or return flow pipe EB 3017 EN...

  • Page 21: Technical Data

    Conformity Depending on how the regulator is config- ured and the process medium used, it can be The Types 42-37 and 42-39 Regulators bear used up to temperatures of 220 °C (see Ta- both the CE and EAC marks of conformity. ble 3-1). The minimum temperature is limited by the accessories used and the actuator's diaphragm material (u T 3017).
  • Page 22 Design and principle of operation Table 3-1: Technical data · Types 42-37 and 42-39 · All pressures in bar (gauge) Type 2423 Valve · Balanced by a bellows Valve size DN 15 to 250 Pressure rating PN 16, 25 or 40 Pressure at which for 160 cm²...
  • Page 23 Design and principle of operation Table 3-2: K coefficients, x values, flow rate set point ranges for water and max. permissible differential pressures Δp Type 2423 Valve balanced by a bellows Valve size DN Valve travel 10 mm 16 mm 22 mm coefficient value 0.65 0.55...
  • Page 24 Design and principle of operation Table 3-3: Materials · Material numbers according to DIN EN Type 2423 Valve · Balanced by a bellows Pressure rating PN 16 PN 25 PN 16, 25 and 40 Spheroidal graphite Forged stainless Cast iron Cast steel Cast stainless Valve body iron EN-GJS-400-...
  • Page 25 Design and principle of operation Table 3-4: Dimensions in mm and weights · Type 2423 Valve balanced by a bellows Valve size Length L Height H1 1.4571 – – – Height H2 Other materials Set point ranges  3) Height H – ØD = 285 mm, 0.1 to Actuator...
  • Page 26 Type 2423 Valve, balanced by a diaphragm ØD V-ring packing For the version with a V-ring packing (e.g. for steam) in DN 15 to 100, add 60 mm to the specified dimension for H2. Fig. 3-5: Dimensions of Type 42-37 and Type 42-39 3-12 EB 3017 EN...

  • Page 27: Shipment And On-Site Transport

    2. Check the shipment for transportation fore installing the valve into the pipeline. damage. Report any damage to They prevent foreign particles from enter- SAMSON and the forwarding agent ing the valve. (refer to delivery note). Î Dispose and recycle the packaging in ac- 3.

  • Page 28: Transporting And Lifting The Regulator

    Shipment and on-site transport 4.3 Transporting and lifting the WARNING regulator Risk of personal injury due to the regulator tipping. Î Observe the regulator's center of gravity. DANGER Î Secure the regulator against tipping over Danger due to suspended loads falling. or turning.

  • Page 29: Lifting The Regulator

    Shipment and on-site transport 4.3.2 Lifting the regulator Lifting 1. Attach one sling to the flange of the To install a large regulator into the pipeline, body and to the rigging equipment (e.g. use lifting equipment (e.g. crane or forklift) hook) of the crane or forklift (see to lift it.

  • Page 30: Storing The Regulator

    Î To keep elastomers in shape and to pre- Î Avoid long storage times. vent cracking, do not bend them or hang Î Contact SAMSON in case of different them up. storage conditions or longer storage Î Store elastomers away from lubricants, times.

  • Page 31: Installation

    Î Make sure the direction of flow matches and are intended as recommendations. Con- the direction indicated by the arrow on tact SAMSON if the lengths are significantly the body. shorter than the recommended lengths. Î Contact SAMSON if the mounting posi- To ensure that the regulator functions proper- tion is not as specified above.
  • Page 32 Installation Support or suspension Standard mounting position, suspended Note All versions. The plant engineering company is responsi- Suitable for steam control and ble for selecting and implementing a suitable for medium temperatures above 80 °C. support or suspension of the installed regula- tor and the pipeline.
  • Page 33 Route the control line on site preferably using a 8x1 mm (stainless) steel pipe. The control line for tapping pressure from the pipeline (for Type 42-37) must be installed upstream of the consumer. The pressure tap- ping point must at least three times the nomi- nal size (DN) away from any pipe fittings (e.g.
  • Page 34 Depending on the conditions, install the com- installing a needle valve in the control line in pensation chamber in the the hot control addition to the standard SAMSON screw line. joint with restriction. Î This mounting position must be adhered to;...
  • Page 35 Installation Correct Connection at the side – optimal Connection at the top – incorrect position Connection at the bottom – incorrect position min. min. 3 x DN 3 x DN min. 3 x DN DN = Valve size Control line connection, depending on how the pipe- line is routed and depending on the components Fig. 5-3: Control line connection EB 3017 EN...

  • Page 36: Preparation For Installation

    Installation 5.2 Preparation for installation Proceed as follows: Î Lay out the necessary material and tools The valve and actuator of regulators that to have them ready during installation have not yet been assembled or have been work. tested beforehand can be assembled before Î...
  • Page 37 No saturated steam Flow and differential pressure control with Flow and differential pressure control with Type 42-37: Type 42-39: Flow and pressure control with Type 42-39: Fig. 5-1: Sample applications for Type 42-37 and Type 42-39 Flow and Differential Pressure or Pressure Regulator EB 3017 EN...

  • Page 38: Final Installation

    Risk of regulator damage due to the use of unsuitable tools. 5. Bolt the pipe to the valve free of stress. Î Only use tools approved by SAMSON Î Additional activities required for indi- (see 'Tools' in Annex). vidual components 6.

  • Page 39: Cleaning The Pipeline

    Installation 5.3.2 Cleaning the pipeline 7. Mount the control line. − Mount the control line onto the valve and We recommend additionally flushing the actuator. Observe the specified tighten- pipeline with installed regulator before start- ing torques (see 'Tightening torques' in Annex).

  • Page 40: Testing The Regulator

    Flying projectile fragments or the re- gloves. lease of process medium under pressure can cause serious injury or even death. SAMSON regulators are delivered ready for Before working on the regulator: use. To test the regulator functioning before Î Depressurize all plant sections concerned start-up or putting back the regulator into and the regulator.

  • Page 41: Leak Test

    The leak test must comply with the The plant operator is responsible for requirements of the national and internation- performing the pressure test. SAMSON's al standards that apply at the site of installa- After-sales Service can support you to plan tion.

  • Page 42: Insulation

    Installation 5.5 Insulation To insulate cold systems, we recommend first filling the plant and carefully rinsing it. The regulator must not yet be insulated at this stage. 1. Start up the plant and adjust the set point (see the 'Start-up' section). 2.

  • Page 43: Start-Up

    Start-up 6 Start-up DANGER The work described in this section is only to Risk of personal injury due to process me- be performed by personnel appropriately dium escaping. qualified to carry out such tasks. Î Do not start up the regulator until all parts have been mounted.

  • Page 44: Starting Up The Plant

    Start-up Before starting up the plant, make sure the ber with the process medium. Proceed as following conditions are met: follows: − The control line is open (needle valve) 1. Unscrew filler plug from the compensa- and correctly connected. tion chamber. 2.

  • Page 45: Operation

    Operation 7 Operation 7.1 Adjusting the set point Immediately after completing start-up or Î The control and shut-off valves as well as placing the regulator back into service (see all consumers or a bypass valve (if in- the 'Start-up' section), the regulator is ready stalled) must be open to ensure that the for use.

  • Page 46: Adjusting The Flow Set Point

    Operation 7.2 Adjusting the flow set point 5. Check the flow rate at the heat meter and correct it, if necessary. 1. Unscrew the cap (1.3). 6. Lock the restriction screw in place with 2. Undo lock nut (1.2). Turn the set point the nut (1.2) and screw the cap (1.3) adjuster (1.4) clockwise as far as it will back on after the required flow rate is...
  • Page 47 Operation V ˚ V ˚ /h ] /h ] ³ ³ DN50 DN25 DN20 DN40 DN25 DN50 DN15 DN40 DN20 DN32 DN15 DN32 Turns of the set point adjuster (restriction)  = 0.5 bar ·  ____  ∆p – – – – ∆p = 0.2 bar restriction restriction V ˚...
  • Page 48 Operation V ˚ V ˚ /h ] ³ /h ] ³ DN125 DN100 12 14 16 18 Turns of the set point adjuster (restriction)  = 0.5 bar ·  ____  ∆p – – – – ∆p = 0.2 bar restriction restriction V ˚ /h ] V ˚ ³...
  • Page 49 Operation V ˚ ˚ V [ m³/h ] [ m³/h ] DN 150 DN 250 DN 200 DN 125 0 2 4 6 8 10 12 14 16 18 0 2 4 6 8 10 12 14 16 18 20 Turns of the set point adjuster (restriction) DN 125, DN 150 · A = 320 cm²...

  • Page 50: Adjusting The Differential Pressure Set Point Of The Type 2427 Actuator (Type 42-37)

    Type 2429 Type 2427 Actuator Actuator (Type 42-39) (Type 42-37) Adjust the pressure set point at the set point adjuster (22) for pressure. While doing so, Î Before adjusting the differential pressure, observe the downstream pressure at the in- close the shut-off valve on the consumer stalled pressure gauge.

  • Page 51: Malfunctions

    Î Remove foreign particles. Foreign particles blocking the plug Î Replace damaged parts. Î Contact SAMSON's After-sales Service. Flow rate, differential Î Replace the damaged seat and plug. pressure or pressure Seat and plug are worn or leak.
  • Page 52 Î Check the sizing. Loud noises High flow velocity, cavitation Î Install larger regulator, if necessary. Leakage at the actua- Defective operating diaphragm Î Replace damaged diaphragm. Note Contact SAMSON's After-sales Service for malfunctions not listed in the table. EB 3017 EN...

  • Page 53: Emergency Action

    3. Rectify those malfunctions that can be remedied based on the instructions SAMSON's After-sales Service can support provided here. Contact SAMSON's you in drawing up an inspection and test After-sales Service in all other cases.
  • Page 54 EB 3017 EN...

  • Page 55: Servicing

    Risk of regulator damage due to the use of ries. unsuitable tools. Î Allow components and pipelines to cool Î Only use tools approved by SAMSON down or warm up to the ambient tem- (see 'Tools' in Annex). perature. Î Wear protective clothing and safety NOTICE gloves.
  • Page 56 Servicing Note The regulator was checked by SAMSON before it left the factory. − Certain test results certified by SAMSON lose their validity when the regulator is Legend for Fig. 9-1 to Fig. 9-3 opened. Such testing includes seat leakage Valve body and leak tests.
  • Page 57 Servicing Type 2423 Valve balanced by a bellows Type 2427 12.1 Actuator 13.1 13.2 12.2 Fig. 9-1: Functional diagram of Type 42-37 Regulator, DN 15 to 250 with balancing bellows EB 3017 EN...
  • Page 58 Servicing Type 2423 Valve balanced by a bellows Type 2429 Actuator Fig. 9-2: Functional diagram of Type 42-39 Regulator, DN 15 to 250 with balancing bellows EB 3017 EN...
  • Page 59 Servicing Type 2423 Valve balanced by a diaphragm Type 2427 Actuator for Type 42-37 or Type 2429 Actuator for Type 42-39 Fig. 9-3: Functional diagram of Type 2423 Valve, DN 65 to 250 with balancing diaphragm EB 3017 EN...

  • Page 60: Preparation For Service Work

    Servicing 9.1 Preparation for service 9.2 Installing the regulator work after service work 1. Lay out the necessary material and tools Î Put the regulator back into operation (see to have them ready for the service work. the 'Start-up' section). Make sure the re- quirements and conditions for start-up or 2.

  • Page 61: Replacing The Actuator

    Replacing the seat and plug Î See Fig. 9-1 to Fig. 9-3 To replace seat and plug, contact Removing the actuator SAMSON's After-sales Service. 1. Put the regulator out of operation (see Further information is available in Annex the 'Decommissioning' section). ('After-sales service').

  • Page 62: Ordering Spare Parts And Operating Supplies

    Servicing 9.4 Ordering spare parts and operating supplies Contact your nearest SAMSON subsidiary or SAMSON's After-sales Service for infor- mation on spare parts, lubricants and tools. Spare parts See Annex for details on spare parts. Lubricant Contact SAMSON's After-sales Service for more information on lubricants.

  • Page 63: Decommissioning

    Decommissioning 10 Decommissioning WARNING The work described in this section is only to Risk of personal injury due to pressurized be performed by personnel appropriately components and process medium being dis- qualified to carry out such tasks. charged. Î Do not loosen the control line while the valve is pressurized.
  • Page 64 Decommissioning WARNING 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 in- jury, e.g. (chemical) burns. Î Wear protective clothing, safety gloves and eye protection.

  • Page 65: Removal

    Removal 11 Removal 11.1 Removing the regulator from the pipeline The work described in this section is only to be performed by personnel appropriately 1. Support the regulator to hold it in place qualified to carry out such tasks. when separated from the pipeline (see the 'Shipment and on-site transport' sec- WARNING tion).
  • Page 66 11-2 EB 3017 EN...

  • Page 67: Repairs

    Î Do not perform any repair work on your downloaded from our website at own. u www.samsongroup.com > Service Î Contact SAMSON's After-sales Service & Support > After-sales Service. for repair work. After checking your registration, we will send you a return merchandise authori- zation (RMA).
  • Page 68 12-2 EB 3017 EN...

  • Page 69: Disposal

    Disposal 13 Disposal Î Observe local, national and internation- al refuse regulations. Î Do not dispose of components, lubricants and hazardous substances together with your household waste. EB 3017 EN 13-1...
  • Page 70 13-2 EB 3017 EN...

  • Page 71: Certificates

    Certificates 14 Certificates The EU declarations of conformity are in- cluded on the next pages: − EU declaration of conformity in compli- ance with Pressure Equipment Directive 2014/68/EU on page 14-2. EB 3017 EN 14-1...
  • Page 72 Certificates Modul H/Module H, Nr./No. / N° CE-0062-PED-H-SAM 001-16-DEU-rev-A SAMSON erklärt in alleiniger Verantwortung für folgende Produkte:/For the following products, SAMSON hereby declares under its sole responsibility: Ventile für Druck-, Differenzdruck-, Temperatur- und Volumenstromregler/Valves for pressure, temperature, flowregulators and differential pressure regulators 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.
  • Page 73 Certificates Modul H/Module H, Nr./No. / N° CE-0062-PED-H-SAM 001-16-DEU-rev-A SAMSON erklärt in alleiniger Verantwortung für folgende Produkte:/For the following products, SAMSON hereby declares under its sole responsibility: Ventile für Druck- Differenzdruck-, Volumenstrom- und Temperaturregler/Valves for pressure, differential pressure, volume flow and temperature regulators 2333 (Erz.-Nr./Model No.
  • Page 74 14-4 EB 3017 EN...

  • Page 75: Annex

    DN 15 to 100 Stopper (35, 50, 53) G  DN 125 to 250 15.2 Lubricant 15.4 Accessories SAMSON's After-sales Service can support Table 15-2: Assignment of compensation you concerning lubricants and sealants ap- chamber (18) to regulator, with item no. proved by SAMSON.  · ...

  • Page 76: Spare Parts

    Annex 15.5 Spare parts Legend for Fig. 15-1 and Fig. 15-2 Bellows 34 Flange Restriction 35 Screw plug 12 Screw 46 Graphite seal on metal core 16 Seat 51 Stud 17 Plug 52 Hex nut 20 Body 81 Cap 21 Guide cap 82 Hex nut 22 Label 132 O-ring...
  • Page 77 Annex Fig. 15-5: Type 2423 Valve, DN 125 to 250 · Balanced by a bellows EB 3017 EN 15-3...
  • Page 78 Annex Legend for Fig. 15-3 Restriction 22 Label Compression spring 27 Cover 10 Diaphragm plate 34 Ring 11 Diaphragm 46 Seal 12 Castle nut 51 Stud 13 Washer 52 Hex nut 14 Plug stem 53 Screw plug 16 Seat 81 Nut 18 Plug 82 Hex nut 19 Screw...
  • Page 79 Annex Legend for Fig. 15-4 Restriction 42 Clamping disk Seat 46 Seal Diaphragm case 47 Diaphragm 11 Cap 49 Screw plug 12 Body 50 Screw plug 17 Label 51 Stud 19 Plug 52 Hex nut 21 Nipple 53 Hex nut 24 Nut 54 Hex nut 38 Diaphragm plate 57 O-ring...
  • Page 80 Screw fitting Force limiter Hex bolt Screw joint with restriction Screw plug Diaphragm Hex nut 10…12 Compression spring Nameplate Screw fitting Axial needle seal with washer 10…12 26…28 Fig. 15-8: Type 2427 Diaphragm Actuator, DN 15 to 250 (Type 42-37) 15-6 EB 3017 EN...
  • Page 81 Annex 10…12 26…28 Fig. 15-9: Type 2429 Diaphragm Actuator, DN 15 to 250 (Type 42-39) EB 3017 EN 15-7...

  • Page 82: After-Sales Service

    E-mail address You can reach our after-sales service at aftersalesservice@samsongroup.com. Addresses of SAMSON AG and its subsid- iaries The addresses of SAMSON, its subsidiaries, representatives and service facilities worldwide can be found on our website (u www.samsongroup.com) or in all...
  • Page 84 EB 3017 EN SAMSON AKTIENGESELLSCHAFT Weismüllerstraße 3 · 60314 Frankfurt am Main, Germany Phone: +49 69 4009-0 · Fax: +49 69 4009-1507 samson@samsongroup.com · www.samsongroup.com...

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