Samson 45-6 Mounting And Operating Instructions
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Samson 45-6 Mounting And Operating Instructions

Differential pressure regulator, self-operated regulators
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EB 3226 EN
Translation of original instructions
Type 45-6 Differential Pressure Regulator
Self-operated Regulators
Edition March 2020

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Summary of Contents for Samson 45-6

  • Page 1 EB 3226 EN Translation of original instructions Type 45-6 Differential Pressure Regulator Self-operated Regulators Edition March 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 Regulator nameplate ...................2-1 Location of the nameplates ................2-1 Material numbers ..................2-1 Design and principle of operation ...............3-1 3.1 Additional fittings ..................3-4...
  • Page 4 Replacing the set point springs ..............9-10 Ordering spare parts and operating supplies ..........9-11 Decommissioning ..................10-1 Removal ....................11-1 11.1 Removing the regulator from the pipeline ............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 Lubricants ....................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 They must observe all hazard statements, warning and caution notes in these mounting and operating instructions. Hazards resulting from the special working conditions at the installation site of the regulator must be identified in a risk assessment and prevented through the corresponding safety instructions drawn up by the operator. We also recommend checking the hazards posed by the process medium being used (e.g. u GESTIS (CLP) hazardous substances database). Î Observe safety measures for handling the device as well as fire prevention and explosion protection measures. Safety features The Type 45-6 Regulator does not have any special safety features. When relieved of pres- sure, the regulator is closed by the force of the set point springs. EB 3226 EN...
  • Page 7 Safety instructions and measures 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. Furthermore, the operator must ensure that operating personnel or third persons are not ex- posed to any danger.

  • Page 8: Notes On Possible Severe Personal Injury

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

  • 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 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 12 Î Keep the regulator and the tools used free from solvents and grease. Î Make sure that only suitable lubricants are used. Note SAMSON's After-sales Service can support you concerning lubricant, tightening torques and tools approved by SAMSON. EB 3226 EN...

  • Page 13: Markings On The Device

    Markings on the device 2 Markings on the device 2.1 Regulator nameplate 1 Model number 2 Material number and device index 3 Order number or year of manufacture 4 Type designation 5 Pressure rating PN coefficient 7 Perm. temperature in °C 8 Set point range in bar 9 Max. perm. differential pressure Δp in bar 10 Arrow indicating the direction of flow...
  • Page 14 Markings on the device EB 3226 EN...

  • Page 15: Design And Principle Of Operation

    (0.1 to 1 bar, DN 15 to 32). The set point Î See Fig. 3-2 and Fig. 3-1 springs are located in the covered housing. The manual adjuster (12) and scale (12.1) The Type 45-6 Differential Pressure Regula- are used for set point adjustment. tors basically consists of the valve with bal- anced plug as well as an opening actuator with an operating diaphragm and spring as- sembly.
  • Page 16 Design and principle of operation 11.1 Fig. 3-1: Functional diagram of the regulator (DN 15 to 50, with external spring) Legend for Fig. 3-1 and Fig. 3-2 Valve body Actuator housing 11 Control line 3.2 Guide nipple 1.1 Coupling nut 6.1 Operating diaphragm 11.1 Borehole in the body Plug nipple Body stopper (DN 32 to 50) 6.2 Spring housing 12 Manual adjuster (DN 32 to 50) 6.3 Diaphragm stem...
  • Page 17 Design and principle of operation 11.1 12.1 12.1 Fig. 3-2: Functional diagram of the regulator (DN 15 to 50, spring housing) EB 3226 EN...

  • Page 18: Additional Fittings

    Design and principle of operation 3.1 Additional fittings Strainers We recommend installing a SAMSON Î See Fig. 3-3 strainer (2) upstream of the valve. It prevents solid particles in the process medium from Pressure gauges damaging the regulator. Install a pressure gauge at a suitable point to Î...

  • Page 19: Technical Data

    Design and principle of operation The regulator is closed when relieved of Note pressure. The valve opens when the differen- The Type 45-6 Regulator is not a safety tial pressure rises. valve. If necessary, a suitable overpressure protection must be installed on site in the Leakage class plant section.
  • Page 20 Design and principle of operation Table 3-1: Technical data · All pressures in bar (gauge) Valve size  1)  1)  1) Body with screwed 12.5 16.0 20.0  4) ends coefficient Flanged body – 12.5 20.0 25.0 Body with screwed 0.55 0.45 ends value Flanged body – 0.45 Pressure rating PN 25...
  • Page 21 Design and principle of operation Table 3-3: Dimensions in mm Valve size Pipe Ø d 21.3 26.8 32.7 42.0 48.0 60.0 Connection R G ¾ G 1 G 1¼ G 1¾ G 2 G 2½ Width across flats SW – ØD Additional version: valve with flanged body Table 3-4: Dimensions in mm and weights · Including connecting parts Valve size With welding ends Overall length L1...
  • Page 22 Design and principle of operation Dimensional drawings Type 45-6 with connection nuts and welding Type 45-6 with connection nuts and welding ends · With rotary knob and scale division · Set ends · DN 40/50 (body with screwed ends) point range 0.1 to 1 bar/DN 15 to 32 Type 45-6 with flanged body valve ØD Connection nuts with threaded ends Connection nuts with flanges ØD The dimensions and weights of valves with flanged bodies (DN 32, 40 and 50) are the same as those of Fig. 3-4: Dimensions the valves with screwed-on flanges. EB 3226 EN...

  • Page 23: Shipment And On-Site Transport

    2. Check the shipment for transportation damage. Report any damage to 4.3 Transporting and lifting the SAMSON and the forwarding agent regulator (refer to delivery note). 3. Determine the weight and dimensions of Due to the low service weight, lifting equip-...

  • Page 24: Storing The Regulator

    Î Observe the storage instructions. Î We recommend a storage temperature of Î Avoid long storage times. 15 °C for elastomers. Î Contact SAMSON in case of different storage conditions or long storage peri- Î Store elastomers away from lubricants, ods. chemicals, solutions and fuels.

  • Page 25: Installation

    Î Contact SAMSON if the mounting posi- Plant operators must ensure that, after instal- tion is not as specified above. lation of the device, the operating personnel can perform all necessary work safely and...

  • Page 26: Preparation For Installation

    Installation 5.2 Preparation for installation Standard mounting position, Before mounting, make sure the following suspended conditions are met: All versions with medium temperature up to 150 °C. − The regulator is clean. − The regulator and all piping are not damaged. Alternative mounting position, upright − Install a strainer upstream of the regula- All versions with medium tor.
  • Page 27 Installation Table 5-1: Inlet and outlet lengths min. min. a x DN b x DN Inlet length Outlet length State of process Valve conditions Inlet length a Outlet length b medium Ma ≤ 0.3 Free of cavitation/w < 3  Liquid Cavitation producing noise/w ≤ 3  Installation in a bypass pipe: Installation in a short-circuit pipe: Shut-off valve Differential pressure Shut-off valve regulator Strainer...

  • Page 28: Assembly And Installation

    NOTICE pipeline without the installed regulator be- Risk of regulator damage due to the use of fore start-up. unsuitable tools. Î Only use tools approved by SAMSON Î Observe the mesh size of the upstream (see Annex). strainer for the maximum particle size. Use strainers to suit the process medium. Î Check the strainer for dirt each time the...

  • Page 29: Testing The Regulator

    Flying projectile fragments or the re- gloves. lease of compressed medium can cause seri- ous 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 30: Pressure Test

    The plant operator is responsible for per- regulator must not yet be insulated at this forming the pressure test. SAMSON's Af- stage. ter-sales Service can support you to plan 1. Start up the plant and adjust the set point and perform a pressure test for your plant.

  • Page 31: 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 qualified for the components and process medium escaping assignment accordingly. under pressure. Î Do not loosen the control line while the valve is pressurized. DANGER Risk of personal injury due to process me- dium escaping under pressure.

  • Page 32: Start-Up And Putting The Regulator Back Into Operation

    Start-up 6.1 Start-up and putting the 6.2 Starting up the plant regulator back into opera- 1. Open the shut-off valve (1) slowly first on tion the upstream pressure side. Open the shut-off valve (6) and all other valves on 1. Depending on the field of application, the downstream pressure side. allow the regulator to cool down or heat 2.

  • Page 33: Operation

    Operation 7 Operation WARNING WARNING Immediately after completing start-up or Crush hazard arising from moving parts. placing the regulator back into service (see Î Do not insert hands or fingers between the 'Start-up' section), the regulator is ready the set point springs while the regulator for use.

  • Page 34: Adjusting The Set Point

    Operation 7.1 Adjusting the set point Note Î The control and shut-off valves as well as Do not adjust the set point to a value on the all consumers must be open. scale lower than 1. Under unfavorable conditions, the set point Manual/set point adjuster cannot be adjusted anymore as a result.

  • Page 35: Malfunctions

    Î Clean the control line and screw fittings. ating diaphragm Î Remove foreign particles. Foreign particles blocking the plug Î Replace damaged parts. Î Contact SAMSON's After-sales Service. Differential Î Replace the damaged seat and plug. pressure exceeds Seat and plug are worn or leak. Î Contact SAMSON's After-sales Service.
  • Page 36 Î Contact SAMSON's After-sales Service. Î Check the sizing. Loud noises High flow velocity, cavitation Î Install larger regulator, if necessary. Leakage at the Defective operating diaphragm Î Replace damaged diaphragm. actuator Note Contact SAMSON's After-sales Service for malfunctions not listed in the table. EB 3226 EN...

  • Page 37: 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 38 EB 3226 EN...

  • Page 39: Servicing

    Servicing 9 Servicing WARNING WARNING The regulator does not require any Crush hazard arising from moving parts. maintenance. Nevertheless, it is subject to Î Do not insert hands or fingers between natural wear, particularly at the seat, plug the set point springs while the regulator and operating diaphragm.
  • Page 40 The regulator was checked by SAMSON servicing or repair. before it left the factory. Service and repair work must be performed − Certain test results certified by SAMSON by trained staff only. lose their validity when the regulator is opened. Such testing includes seat leakage and leak tests.
  • Page 41 Servicing 6.2 Spring housing Legend for Fig. 9-1 and Fig. 9-2 6.3 Diaphragm stem Valve body 3.3 Plug assembly (DN 32 to 50) Housing screws 1.1 Coupling nut 3.4 Plug stem Set point spring 1.2 Body stopper 3.5 Seal Spring plate 1.3 Seal 3.6 Balancing piston 10 Set point adjuster Seat Diaphragm plate nut 11 Control line Plug (balanced) Diaphragm plate...
  • Page 42 Servicing 11.1 12.1 Fig. 9-2: Functional diagram of the regulator (DN 15 to 50, spring housing with manual adjuster) EB 3226 EN...

  • Page 43: Preparing The Valve For Service Work

    Servicing 9.1 Preparing the valve for 9.2 Installing the regulator service 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 44: Replacing The Seat And Plug

    12. Check the control line (11) for any block- ages. 13. Unscrew the seat (2) using a seat wrench SW 19 if the seat facing is damaged. SAMSON order no. 1280-3001 Î See Fig. 9-2 and Fig. 9-1 EB 3226 EN...
  • Page 45 Servicing Mounting the seat and plug 10. Put the regulator back into operation (see the 'Start-up' section). 1. Screw in the seat (2) using a seat wrench. Observe the specified tightening torques (see 'Tightening torques' in An- nex). 2. Renew the seal (3.5) and insert it into the valve body.

  • Page 46: Replacing The Operating Diaphragm

    4. Unscrew the control line (11). Parts that are too loose may cause leakage. 5. Use the SAMSON disassembly tool to Observe the specified tightening torques. unscrew the set point adjuster (10) from the diaphragm stem (7).
  • Page 47 (1) and tighten the body screws (7) evenly. Observe the specified tightening torques (see 'Tightening torques' in Annex). 6. Use the SAMSON disassembly tool to screw the valve body (1) together with spring plate (9) and the set point spring (8). 7. Screw the set point adjuster (10) onto the diaphragm stem (6.3).

  • Page 48: Replacing The Set Point Springs

    4. Unscrew the control line (11). Parts that are too loose may cause leakage. 5. Use the SAMSON disassembly tool to Observe the specified tightening torques. unscrew the set point adjuster (10) from the diaphragm stem (7).

  • Page 49: 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. Lubricants See Annex for details on lubricants.
  • Page 50 Servicing 9-12 EB 3226 EN...

  • Page 51: Decommissioning

    Decommissioning 10 Decommissioning WARNING The work described in this section is only to Risk of hearing loss or deafness due to loud be performed by personnel qualified for the noise. assignment accordingly. Noise emission (e.g. cavitation or flashing) may occur during operation caused by the process medium and the operating condi- DANGER tions.
  • Page 52 Decommissioning To decommission the regulator for service work or disassembly, proceed as follows: 1. Close the shut-off valve (1) on the up- stream side of the regulator. 2. Close the shut-off valve (6) on the down- stream side of the regulator. 3.

  • Page 53: 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 qualified for the 1. Support the regulator to hold it in place assignment accordingly. when separated from the pipeline (see the 'Shipment and on-site transport' sec- WARNING tion).
  • Page 54 11-2 EB 3226 EN...

  • Page 55: Repairs

    Î Do not perform any repair work on your After checking your registration, we will own. send you a return merchandise authori- Î Contact SAMSON's After-sales Service zation (RMA). for repair work. 6. Attach the RMA (together with the Declaration on Decontamination) to the 12.1 Returning devices to...
  • Page 56 12-2 EB 3226 EN...

  • Page 57: 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 3226 EN 13-1...
  • Page 58 13-2 EB 3226 EN...

  • Page 59: 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 3226 EN 14-1...
  • Page 60 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 61 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 62 14-4 EB 3226 EN...

  • Page 63: Annex

    Diaphragm plate nut (4) SW 19 DN 40 to 50 SW 10 DN 15 to 32 Body screws (7) SW 13 DN 40 to 50 Control line connection (11) – 15.2 Lubricants Table 15-2: Lubricant Lubricant Item no. Gleitmo 591 8150-0111 15.3 Tools SAMSON's After-sales Service can support you concerning tools approved by SAMSON. EB 3226 EN 15-1...

  • Page 64: Spare Parts

    Annex 15.4 Spare parts Legend for Fig. 15-1 and Fig. 15-2 Restriction Plug stem Body stopper Plug Plug assembly (DN 32 to 50) Pre-stage of plug Valve body Guide nipple Seat 31…34 Plug spring Set point adjuster Spring plate Diaphragm plate nut Seal Set point springs 70…78 Balancing piston Diaphragm stem Seal Diaphragm plate Plug nipple nut Spring plate Plug nut 103…105 Washer...
  • Page 65 Annex 186, 187 31…34 134, 135 129…131 Fig. 15-1: R egulator (DN 15 to 50, spring housing) EB 3226 EN 15-3...
  • Page 66 Annex 186, 187 31…34 134, 135 124, 125 129…131 7, 155 70…78 103…105 Fig. 15-2: R egulator (DN 15 to 50, with external spring) 15-4 EB 3226 EN...

  • Page 67: 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 SAMSON product catalogs. Required specifications Please submit the following details: −...
  • Page 68 Annex 15-6 EB 3226 EN...
  • Page 72 EB 3226 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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