Samson 42-24 Mounting And Operating Instructions
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Samson 42-24 Mounting And Operating Instructions

Differential self-operated pressure regulators
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EB 3003 EN
Translation of original instructions
Type 42-24 Differential
Pressure Regulator
Type 42-24 and Type 42-28 Differential Pressure Regulators
Self-operated Regulators
Edition July 2020
Type 42-28 Differential
Pressure Regulator

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Summary of Contents for Samson 42-24

  • Page 1 EB 3003 EN Translation of original instructions Type 42-28 Differential Type 42-24 Differential Pressure Regulator Pressure Regulator Type 42-24 and Type 42-28 Differential Pressure Regulators Self-operated Regulators Edition July 2020...
  • Page 2 Note on these mounting and operating instructions These mounting and operating instructions assist you in mounting and operating the device safely. The instructions are binding for handling SAMSON devices. The images shown in these instructions are for illustration purposes only. The actual product may vary.

  • 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 number ..................2-2 2.3.1 Type 2422 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 − Safety footwear, ESD (electrostatic discharge) footwear, if necessary 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 Start-up and shutdown procedures fall within the scope of the operator's duties and, as such, are not part of these mounting and operating instructions. SAMSON is unable to make any statements about these procedures since the operative details (e.g. differential pressures and temperatures) vary in each individual case and are only known to the operator.

  • 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 e.g. Type 2 N/NI Strainer 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 Risk of personal injury through incorrect operation, use or installation as a result of information on the regulator being illegible. Over time, markings, labels and nameplates on the regulator may become covered with dirt or become illegible in some other way. As a result, hazards may go unno- ticed and the necessary instructions not followed.
  • Page 10 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 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 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 the 'Installation' section. Note SAMSON's After-sales Service can support you concerning lubricant, tightening torques and tools approved by SAMSON. EB 3003 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 2422 Valve DIN version ANSI version ANSI version · DIN version Valve type Model number with index Unassigned Perm. differential pressure Material number Valve size 10 Perm. temperature Order number or date Pressure rating 11 Body material...

  • Page 14: Location Of The Nameplates

    Markings on the device 2.2 Location of the nameplates 2.3 Material number 2.3.1 Type 2422 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 Type 2424 and Type 2428 Actuators Specifying the material number, you can contact us to find out which material is used.

  • Page 15: Design And Principle Of Operation

    This force moves the plug according to lines to a defined set point. the force of the set point springs (16). Type 42-24 · The set point can be adjusted The set point springs are mounted inside the as required within the set point range. actuator for a fixed set point (Type 42-28). The set point springs can be adjusted exter- Type 42-28 · The set point is fixed.
  • Page 16 Design and principle of operation Type 42-24 Type 42-28 Type 2422 Valve, balanced by a bellows (DN 15 to 250) Type 2424 Actuator Type 2428 Actuator Fig. 3-1: Functional diagram for regulators, DN 15 to 250 with balancing bellows EB 3003 EN...
  • Page 17 Design and principle of operation Type 42-24 Type 42-28 Type 2422 Valve, balanced by a diaphragm (DN 65 to 250) – Type 2424 Actuator Type 2428 Actuator Fig. 3-2: Functional diagram for regulators, DN 65 to 250 with balancing diaphragm Legend for Fig. 3-1 and Fig. 3-2 Valve body 11 Coupling nut 18 Nut 22 Diaphragm stem...

  • Page 18: Additional Fittings

    Pressure gauge (return flow Motorized valve pipe) Pressure gauge (flow pipe) Needle valve Compensation chamber (optional) Fig. 3-3: Installation example: Type 42-24 and Type 42-28 installed in the flow and return flow pipe. The control lines to be installed on site are represented by a dashed line. EB 3003 EN...

  • Page 19: Technical Data

    The Type 42-24 and Type 42-28 Regulators bear both the CE and EAC marks of confor- mity. Note The Type 42-24 and Type 42-28 Regulators are not safety valves. If necessary, a suitable overpressure protection must be installed on Process medium and scope of application site in the plant section.
  • Page 20 Design and principle of operation Leakage class Noise emissions The metal-seated regulator has the leakage SAMSON is unable to make general state- class I according to IEC 60534-4. ments about noise emissions. The noise emis- The soft-seated regulator has the leakage sions depend on the regulator version, plant class IV according to IEC 60534-4.
  • Page 21 Design and principle of operation Table 3-2: Materials · Material numbers according to DIN EN Type 2422 Valve · Balanced by a bellows Valve size DN 15 to 250 Pressure rating PN 16 PN 25 PN 16, 25, 40 Cast iron Sph. graphite iron Cast steel Cast stainless steel Forged stainless Valve body EN-GJL-250...
  • Page 22 Design and principle of operation Table 3-3: K coefficients, x values and max. permissible differential pressures ∆p Type 2422 Valve · Balanced by a bellows Valve size DN 200 250 Valve travel 10 mm 16 mm 22 mm coefficient 420 500 Max. permissible differential 25 bar 20 bar 16 bar...
  • Page 23 Design and principle of operation Table 3-4: Dimensions and weights for Type 42-24 and Type 42-28 · Balanced by a bellows Dimensions in mm · Weights in kg (without process medium) Valve size Length L 130  150 Up to 220 °C Height H1 Up to 350 °C Forged steel –...
  • Page 24 Design and principle of operation Table 3-5: Dimensions and weights for Type 42-24 and Type 42-28 · Balanced by a diaphragm Dimensions in mm · Weights in kg (without process medium) Valve size DN Length L Height H1 Height H2 Type 42-28 Differential Pressure Regulator Set points Type 2428 Actuator...
  • Page 25 Design and principle of operation Dimensional drawings Type 42-24 Type 42-28 Type 2422 Valve balanced by a bellows with Type 2422 Valve balanced by a bellows with Type 2424 Actuator Type 2428 Actuator Ø D Type 42-24 Type 2422 Valve balanced by a bellows with Type 2424 Actuator and metal cover Ø...
  • Page 26 Design and principle of operation Dimensional drawings Type 42-24 Type 42-28 Type 2422 Valve balanced by a diaphragm with Type 2422 Valve balanced by a diaphragm with Type 2424 Actuator Type 2428 Actuator Actuator with two diaphragms Type 42-24 with two diaphragms: Add approx. 55 mm to the total height H. Fig. 3-5: Dimensions · Type 2422 Valve balanced by a diaphragm...

  • Page 27: Shipment And On-Site Transport

    2. Check the shipment for transportation They prevent foreign particles from enter- damage. Report any damage to ing the valve. SAMSON and the forwarding agent Î Dispose and recycle the packaging in (refer to delivery note). accordance with the local regulations.

  • 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 Transport instructions Lifting Î Protect the regulator against external 1. Attach one sling to the flange of the influences (e.g. impact). body and to the rigging equipment (e.g. hook) of the crane or forklift (see Î Do not damage the corrosion protection Fig. 4-1). (paint, surface coatings). Repair any damage immediately.

  • 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

    To ensure that the regulator functions proper- Î Contact SAMSON if the mounting posi- ly, proceed as follows: tion is not as specified above. Î Observe the inlet and outlet lengths (see Table 5-1).
  • Page 32 Installation Support or suspension NOTICE Damage due to freezing. Note Protect the regulator from icing up when con- The plant engineering company is responsi- trolling media that can freeze. Unless the ble for selecting and implementing a suitable regulator is installed in locations where no support or suspension of the installed regula- frost occurs, remove the regulator from the tor and the pipeline.
  • Page 33 Needle valve Correct If the regulator tends to hunt, we recommend installing a needle valve in the control line in addition to the standard SAMSON screw joint with restriction. Connection at the side – optimal Compensation chamber A compensation chamber (18) is required for liquids above 150 °C as well as for...

  • Page 34: Preparation For Installation

    Installation 5.2 Preparation for installation Î Check any mounted pressure gauges to make sure they function properly. Valve and actuator can be assembled before or after the valve has been installed in the pipeline. We recommend first installing the valve without the actuator into the pipeline. Before installation, make sure the following conditions are met: −...
  • Page 35 Pressure gauge (return flow pipe) Needle valve Pressure gauge (flow pipe) Shut-off valve Compensation chamber (optional) Fig. 5-3: Installation example: Type 42-24 and Type 42-28 installed in the flow and return flow pipe. The control lines to be installed on site are represented by a dashed line. EB 3003 EN...

  • Page 36: Final Installation

    Risk of regulator damage due to the use of physical fitness. unsuitable tools. Î When the actuator is filled with medium, Î Only use tools approved by SAMSON take the weight of the medium also into (see 'Tools' in Annex). account.

  • Page 37: Installing The Regulator

    Installation ening torques (see 'Tightening torques' in NOTICE Annex). Risk of regulator damage due to exces- 7. Mount the control lines to be installed on sively high or low tightening torques. site. Observe the specified torques when tighten- − Mount the control lines to be installed on ing regulator components.

  • Page 38: Testing The Regulator

    The regulator components are delivered by Before working on the regulator: SAMSON ready for use. To test the regulator Î Depressurize all plant sections concerned functioning before start-up or putting back and the regulator.

  • Page 39: 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 40: 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. Shut down the plant again and let it heat up until the condensation water has dried off.

  • Page 41: Start-Up

    Start-up 6 Start-up 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 qualified to carry out such tasks. discharged. Î Do not loosen the control line while the valve is pressurized.

  • Page 42: Starting Up The Plant

    Start-up 6.2.1 Regulation of liquids Before starting up the plant, make sure the following conditions are met: Î To start up the differential pressure − The control lines are open (needle valve) regulator, open shut-off valves slowly and correctly connected. (depending on the state of the process medium).

  • Page 43: Operation

    'Start-up' section), the regulator is ready all consumers or a bypass valve (if in- for use. stalled) must be open. Type 42-24 WARNING Adjust the required set point by tensioning Risk of burn injuries due to hot or cold the set point springs at the set point adjuster components and pipeline.
  • Page 44 EB 3003 EN...

  • Page 45: Malfunctions

    Î Remove foreign particles. Foreign particles blocking the plug Î Replace damaged parts. Î Contact SAMSON's After-sales Service. Î Replace the damaged seat and plug. Seat and plug are worn or leak. Î Contact SAMSON's After-sales Service. Differential pressure exceeds adjusted set Î...
  • Page 46 Î Replace damaged parts. response particles between seat and plug Î Contact SAMSON's After-sales Service. Î Check the sizing. Loud noises High flow velocity, cavitation Î Install larger regulator, if necessary. Note Contact SAMSON's After-sales Service for malfunctions not listed in the table. EB 3003 EN...

  • Page 47: 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 48 EB 3003 EN...

  • Page 49: Servicing

    Servicing 9 Servicing DANGER The regulator does not require any mainte- Danger due to suspended loads falling. nance. Nevertheless, it is subject to natural Î Stay clear of suspended or moving wear, particularly at the seat, plug and oper- loads. ating diaphragm.
  • Page 50 Risk of regulator damage due to the use of Î When the actuator is filled with medium, unsuitable tools. take the weight of the medium also into Î Only use tools approved by SAMSON account. (see 'Tools' in Annex). Î Refer to the 'Design and principle of...
  • Page 51 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 opened. Such testing includes seat leakage and leak tests. − The product warranty becomes void if...
  • Page 52 Servicing Type 42-24 Type 42-28 Type 2422 Valve, balanced by a bellows (DN 15 to 250) Type 2424 Actuator Type 2428 Actuator Fig. 9-1: Functional diagram for regulators, DN 15 to 250 with balancing bellows EB 3003 EN...
  • Page 53 Servicing Type 42-24 Type 42-28 Type 2422 Valve, balanced by a diaphragm (DN 65 to 250) – Type 2424 Actuator Type 2428 Actuator Fig. 9-2: Functional diagram for regulators, DN 65 to 250 with balancing diaphragm EB 3003 EN...

  • Page 54: Preparing The Valve For Service Work

    Servicing 9.1 Preparing the valve for 9.3 Service work service work Î Before performing any service work, preparations must be made to the regu- 1. Lay out the necessary material and tools lator (see section 9.1). to have them ready for the service work. Î...

  • Page 55: Replacing The Seat And Plug

    (23). To replace seat and plug, contact Installing the operating diaphragm unit SAMSON's After-sales Service. 1. Insert the new operating diaphragm unit Further information is available in Annex into the bottom diaphragm case (23).

  • Page 56: Ordering Spare Parts And Operating Supplies

    Lift off the top diaphragm case Contact your nearest SAMSON subsidiary (14) including the operating diaphragm or SAMSON's After-sales Service for infor- unit (consisting of items 13, 18, 19, 21 mation on spare parts, lubricants and tools. and 22).

  • Page 57: 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 qualified to carry out such tasks. discharged. Î Do not loosen the control line while the valve is pressurized.
  • Page 58 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 59: 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 60 11-2 EB 3003 EN...

  • Page 61: Repairs

    7. Send the shipment to the address given Risk of regulator damage due to incorrect on the RMA. service or repair work. Î Contact SAMSON's After-sales Service Note for repair work. Further information on returned devices and how they are handled can be found at 12.1 Returning devices to...
  • Page 62 12-2 EB 3003 EN...

  • Page 63: 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 3003 EN 13-1...
  • Page 64 13-2 EB 3003 EN...

  • Page 65: Certificates

    − EU declaration of conformity in compli- ance with Pressure Equipment Directive 2014/68/EU on page 14-2. − EU declaration of conformity in compli- ance with Machinery Directive for Type 42-24 and Type 42-28 Regulators on page 14-3. − Declaration of incorporation in compli- ance with Machinery Directive 2006/42/EC for the Type 2422 Valve with other actuators other than the Type 2424 and Type 2428 Actuators on...
  • Page 66 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 67 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 68 14-4 EB 3003 EN...
  • Page 69 EB 3003 EN 14-5...
  • Page 70 14-6 EB 3003 EN...

  • Page 71: Annex

    Diaphragm plate nut (18) SW 12 40 to 640 cm² Control line connection (20) – 40 to 640 cm² 15.2 Lubricant SAMSON's After-sales Service can support you concerning lubricants and sealants ap- proved by SAMSON. 15.3 Tools SAMSON's After-sales Service can support you concerning tools approved by SAMSON.

  • Page 72: Spare Parts

    Annex 15.5 Spare parts Legend for Fig. 15-1 and Fig. 15-2 Body 97 Flange Bottom section 109 Nameplate Seat 500 Bellows Plug 502 Balancing screw 12 Washer 506 Connecting nipple 13 Bolt 507 Guide cap 14 Nut 525 Compression spring 18 Guide bushing 558 Washer 19 Guide tube 596 Retaining washer 36 Nipple...
  • Page 73 Annex Fig. 15-2: Type 2422 Valve, DN 15 to 250 · Balanced by a bellows EB 3003 EN 15-3...
  • Page 74 Annex Legend for Fig. 15-3 Diaphragm case Bolt Diaphragm case Diaphragm stem with excess Adhesive label + pressure limiter and diaphragm Adhesive label - Coupling nut 28…31 Compression spring Spring plate Nameplate Diaphragm Screw joint with restriction 28…31 Fig. 15-3: Type 2428 Diaphragm Actuator, DN 15 to 250 15-4 EB 3003 EN...
  • Page 75 Annex Legend for Fig. 15-4 Diaphragm case Adhesive label + Diaphragm case Adhesive label - Nipple Nameplate Guide nipple Nut of set point adjuster Diaphragm stem with excess 27…29 Set point springs pressure limiter and diaphragm Compression spring Force limiter Spring plate Coupling nut Axial needle bearing Bolt Washer...

  • Page 76: 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 78 EB 3003 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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42-28

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