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EB 2512 EN Translation of original instructions Type 41-23 Universal Pressure Reducing Valve Self-operated Pressure Regulators Edition January 2024...
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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.
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 .............1-6 Warnings on the regulator ................1-9 Markings on the device ................2-1 Nameplates ....................2-1 Location of the nameplates ................2-2 2.3 Material identification number ..............2-2 2.3.1...
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Removal ....................11-1 11.1 Removing the valve 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 14.1 Information on the UK sales region .............14-1 Appendix ....................15-1 15.1 Tightening torques ..................15-1...
Therefore, operators must ensure that the regulators are only used in operating conditions that meet the specifications used for sizing the devices at the ordering stage. In case operators intend to use the regulators in applications or conditions other than those 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. Î Refer to the technical data and nameplate for limits and fields of application as well as possible uses.
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Plant operators and operat- ing personnel must observe all hazard statements, warnings 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 in- structions 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 41-23 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. EB 2512 EN...
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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.
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. Accessories: Compensation chamber u EB 2595 e.g. Type 2 NI Strainer u EB 1015 − Data sheets for Accessories: Compensation chamber · Screw fittings · Control e.g.
Safety instructions and measures 1.2 Notes on possible personal injury WARNING Risk of hearing loss or deafness due to loud noise. The noise emissions depend on the valve version, plant facilities and process medium. Î Wear hearing protection when working near the valve. Crush hazard arising from moving parts.
WARNING Damage to health relating to the REACH regulation. If a SAMSON device contains a substance listed as a substance of very high concern on the candidate list of the REACH regulation, this is indicated on the SAMSON deliv- ery note.
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Risk of regulator damage due to the use of unsuitable lubricants. 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 regulator damage due to incorrectly attached slings.
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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' chapter. Note SAMSON's After-sales Service can support you concerning lubricant, tightening torques and tools approved by SAMSON. EB 2512 EN...
Safety instructions and measures 1.4 Warnings on the regulator Warning Meaning of the warning Location on the device symbols Attention ! Warning to indicate that the set point springs are loaded. Do not disassemble the There is a risk of serious head or face injury through the valve without sudden release of the set point springs while unscrewing relieving the...
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Safety instructions and measures 1-10 EB 2512 EN...
Markings on the device 2 Markings on the device Several nameplates are affixed to the device. the ones shown. The nameplates are used to The nameplates shown were up to date at identify the separate regulator components the time of publication of this document. The (see Fig. 2-1). nameplates on the device may differ from 2.1 Nameplates Valve nameplate...
Chapter 2.1. regulator components 2.3.2 Type 2413 Actuator Specifying the material number, you can contact SAMSON to find out which material is used. It is specified on the nameplate in the 'Mat.-No.' field (3 for DIN/ANSI). For Fig. 2-2: Nameplate of the Type 2412 Valve more details on the nameplate, see Chap- and on the Type 2413 Actuator ter 2.1. (diaphragm or bellows)
Î See Fig. 3-1 Depending on the valve and actuator used, The Type 41-23 Pressure Reducing Valve the regulator can be upgraded to create a consists of a Type 2412 Closing Valve and a pressure reducing valve for low flow rates, a Type 2413 Actuator. The valve and actuator steam pressure reducing valve or a pressure...
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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. 3-1: Functional diagram for regulators, DN 32 to 100 with balancing bellows EB 2512 EN...
Any impurities carried along by the process medium may impair the proper functioning Strainers of the regulator. We recommend installing a We recommend installing a SAMSON strainer (e.g. SAMSON Type 2 NI) upstream strainer (2) upstream of the valve. It prevents of the pressure reducing valve (u EB 1015).
− Pressure ratings from PN 16 to 40 The regulator is open when relieved of pres- Note sure. The valve closes when the downstream The Type 41-23 Regulator does not have a pressure rises. safety valve. If necessary, a suitable over- pressure protection must be installed on site.
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Design and principle of operation Noise emissions Dimensions and weights SAMSON is unable to make general state- Table 3-5 provides a summary of the dimen- ments about noise emissions. The noise emis- sions and weights. The lengths and heights sions depend on the regulator version, plant...
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8 bar 20 to 28 bar 2 bar Note The Type 41-23 Regulator does not have a safety valve. If necessary, a suitable overpressure protection must be installed on site. Note The maximum permissible pressure at the actuator depends on the currently adjusted set point. Add the value listed in the table to it.
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Bellows – CrNiMo steel In corrosion-resistant version (CrNi steel) Table 3-5: Dimensions in mm and weights in kg Universal Pressure Reducing Valve Type 41-23 Nominal 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 –...
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Design and principle of operation Table 3-5: Dimensions in mm and weights in kg Universal Pressure Reducing Valve Type 41-23 Nominal size DN 15 DN 20 DN 25 DN 32 DN 40 DN 50 DN 65 DN 80 DN 100 Height H4 Standard version with Type 2413 Diaphragm Actuator Height H 3) 0.05 to Actuator ØD = 380 mm, A = 640 cm²...
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Design and principle of operation Table 3-5: Dimensions in mm and weights in kg Universal Pressure Reducing Valve Type 41-23 Nominal size DN 15 DN 20 DN 25 DN 32 DN 40 DN 50 DN 65 DN 80 DN 100 Version with Type 2413 Bellows Actuator Height H 2 to Actuator ØD = 120 mm, A = 62 cm² 6 bar Valve spring force F 4400 N Height H...
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Design and principle of operation Dimensional drawings ØD ØD Type 41-23 with diaphragm actuator Type 41-23 with bellows actuator Fig. 3-4: Dimensions 3-10 EB 2512 EN...
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 (re- ing the valve. fer to delivery note). Î Dispose and recycle the packaging in ac- 3.
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 Risk due to suspended loads falling. or turning.
Shipment and on-site transport 4.3.2 Lifting the regulator 5. After installation in the pipeline, check whether the regulator flanges are bolted To install a large regulator into the pipeline, tight. use lifting equipment (e.g. crane or forklift) 6. Remove slings. to lift it. Lifting instructions Î...
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 long storage peri- Î Store elastomers away from lubricants, ods.
Î Make sure the direction of flow matches tion. the direction indicated by the arrow on the body. Pipeline routing Î Contact SAMSON if the mounting posi- The inlet and outlet lengths vary depending tion is not as specified above. on several variables and process conditions and are intended as recommendations. Con-...
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(see Table 5-1 and Fig. 5-2). Fig. 5-1: Mounting position Control line kit A control line kit for tapping pressure at the On request: Permissible for regulators with valve body is available as an accessory part fixed plug stem guide plus with medium temperature up to 80 °C. Not for steam. from SAMSON. EB 2512 EN...
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(16) in addition to the standard with a downward slope. In this case, use a SAMSON screw joint with restriction. “ pipe with screw fittings. EB 2512 EN...
Installation 5.2 Preparation for installation Proceed as follows: Î Lay out the necessary material and tools Valve and actuator can be assembled before to have them ready during installation or after the valve has been installed in the work. pipeline. We recommend first installing the Î Flush the pipeline before installing the valve without the actuator into the pipeline.
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Installation Table 5-1: Inlet and outlet lengths (example) min. min. a x DN b x DN Control line (e.g. control line kit, see information under “Control line” in Chapter 5.1) Inlet length Outlet length State of process Valve conditions Inlet length a Outlet length b medium Ma ≤ 0.3 Vapors...
Risk of regulator damage due to the use of unsuitable tools. Î Bellows actuator DN 15 to 50 Î Only use tools approved by SAMSON − Remove the crossbeam (8) from the (see 'Tools' in the Appendix). valve. − Insert the actuator stem (11) into the trav- el stop cap with cotter pin (20).
Installation 5.3.2 Cleaning the pipeline Î Bellows actuator DN 65 to 100 − Remove the crossbeam (8) from the We recommend additionally flushing the valve. pipeline with installed regulator before start- − Unscrew the pillars (8.1). − Screw the pillars (8.1) into the threaded Î Unscrew the control line (17) from the holes (8.3) of the actuator flange as far valve body.
Î Do not start up the regulator until all Î Wear protective clothing and safety parts have been mounted. gloves. SAMSON regulators are delivered ready for WARNING use. To test the regulator functioning before Risk of hearing loss or deafness due to loud start-up or putting back the regulator into noise.
5. Rework any parts that leak and repeat the leak test. 5.4.2 Pressure test Note The plant operator is responsible for per- forming the pressure test. SAMSON's Af- ter-sales Service can support you to plan and perform a pressure test for your plant. EB 2512 EN...
Installation 5.5 Insulation 5.5.2 Cold insulation To insulate cold systems, we recommend first 5.5.1 Insulation for medium filling the plant and carefully rinsing it. The temperatures above regulator must not yet be insulated at this stage. 150 °C Only the valve body is to be insulated up to NOTICE the set point springs at the most for medium Risk of regulator damage due to incorrect temperatures above 150 °C.
Start-up 6 Start-up WARNING The work described in this chapter 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.
Start-up 6.2 Starting up the plant − The prevailing conditions in the plant section concerned meet the regulator siz- ing requirements (see information under WARNING 'Intended use' in the 'Safety instructions Risk of personal injury due to process me- and measures' chapter). dium escaping. Depending on the conditions in the plant in 6.1 Start-up and putting the operation, it may be necessary to install device back into operation...
Start-up 6.2.1 Regulation of liquids 6.2.2 Regulation of steam Î For liquid medium temperatures above Î Warm up the plant very slowly. During 150 °C, first fill the compensation cham- this procedure, drain off any condensate ber with the process medium. Proceed as and vent the plant. follows: Î...
Operation 7 Operation WARNING Immediately after completing start-up or Crush hazard arising from moving parts. placing the regulator back into operation Î Do not insert hands or fingers between (see the 'Start-up' chapter), the regulator is the set point springs while the regulator ready for use.
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Operation An initial adjustment of the set point can also Table 7-1: Set point adjustment · Dimension be made by changing the spring tension un- til the distance x (see Fig. 7-1 and Table 7-1) Set point is reached. Nominal size DN range 8 to 16 bar 15 to 25 32 to 50 65 to 100 10 bar...
Î Clean the control line and screw fittings. Î Remove foreign particles. Foreign particles blocking the plug Î When parts are damaged, contact SAMSON's After-sales Service. Î When parts are damaged, contact SAMSON’s Seat and plug are worn or leak. After-sales Service. Downstream pressure Control line blocked Î...
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Î Remove foreign particles. Foreign particles blocking the plug Î When parts are damaged, contact SAMSON’s After-sales Service. Compensation chamber in the wrong Î Reconnect compensation chamber at a different position or too small (with steam) place or replace it (see the Appendix).
Malfunctions 8.2 Emergency action Note Contact SAMSON’s After-sales Service for The plant operator is responsible for emer- malfunctions not listed in the table. gency action to be taken in the plant. We recommend removing the regulator from The malfunctions listed in Chapter 8.1 are the pipeline before repairing it.
Risk of regulator damage due to the use of become very hot or cold. Risk of burn inju- unsuitable tools. ries. Î Only use tools approved by SAMSON Î Allow components and pipelines to cool (see the Appendix). down or heat up.
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Servicing Note The regulator was checked by SAMSON before it left the factory. − Certain test results (seat leakage and leak test) certified by SAMSON lose their validity when the regulator is opened. − The product warranty becomes void if Legend for Fig. 9-1...
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Servicing 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. 9-1: Functional diagram for regulators, DN 32 to 100 with balancing bellows EB 2512 EN...
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 Chapter 9.1). to have them ready for the service work. Î...
Servicing 9.3.1 Replacing the actuator Mounting the actuator 1. Diaphragm actuator DN 15 to 100 Î Refer to Fig. 9-1 Insert the actuator stem (11) through the Removing the actuator hole in the crossbeam (8) into the travel stop cap with cotter pin (20) and fasten 1.
Servicing 9.3.2 Replacing the set point Mounting the set point springs springs 1. Place the set point springs (7) on the set point adjuster (6). Î Refer to Fig. 9-1 2. Place on the spring plate (7.1) and the Removing the set point springs travel stop cap with cotter pin (20).
Do not exchange the operating diaphragm in an FDA-compliant regulator version. 3. Unscrew the control line (17). SAMSON's After-sales Service can support 4. Unscrew the nuts (9) and remove the you to perform such service work. actuator. 5. Clamp the actuator stem (11) into a suitable fixture. Mark the side of the...
1. Place a new operating diaphragm (12) onto the diaphragm plate (13) (ensuring Contact your nearest SAMSON subsidiary the pressurized side is facing in the cor- or SAMSON's After-sales Service for infor- rect direction) and tighten the diaphragm mation on spare parts, lubricants and tools. plate nut (14). Observe the tightening torques specified in the Appendix.
Decommissioning 10 Decommissioning WARNING The work described in this chapter 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 bursting due to incorrect opening of pressurized equipment or components.
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Decommissioning To decommission the regulator for service WARNING WARNING work or disassembly, proceed as follows: Risk of personal injury due to residual 1. Close the shut-off valve (1) on the up- process medium in the regulator. stream side of the regulator. While working on the regulator, residual 2.
Removal 11 Removal Before removing the valve, make sure the fol- lowing conditions are met: The work described in this chapter is only to − The control valve is put out of operation be performed by personnel qualified for the (see the 'Decommissioning' chapter). assignment accordingly. 11.1 Removing the valve from WARNING the pipeline...
Î Do not perform any repair work on your own. 3. Fill in the Declaration on Contamination, Î Contact SAMSON's After-sales Service which can be downloaded from our for repair work. website at u www.samsongroup.com > Service > After-sales Service.
Disposal 13 Disposal SAMSON is a producer registered at the following European institution u https://www.ewrn.org/ national-registers/national- registers. WEEE reg. no.: DE 62194439/FR 025665 Î Observe local, national and internation- al refuse regulations. Î Do not dispose of components, lubricants and hazardous substances together with your other household waste.
2016 No. 1105 (UKCA marking). It does not apply to Northern Ireland. − EU declaration of conformity in Importer compliance with Machinery Directive 2006/42/EC for Type 41-23 Regulator SAMSON Controls Ltd on page 14-5. Perrywood Business Park Honeycrock Lane − Declaration of incorporation in Redhill, Surrey RH1 5JQ compliance with Machinery Directive 2006/42/EC for Type 2412 Valve and...
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ANSI, body, A216 WCC and A351 CF8M, NPS 2½-6, Class 150, all fluids ANSI, body, A216 WCC and A351 CF8M, NPS 1½-6, Class 300, all fluids Revision 00 Classification: Public · SAMSON AKTIENGESELLSCHAFT · Weismuellerstrasse 3 · 60314 Frankfurt am Main, Germany Page 1 of 3 14-2...
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DIN EN, body, EN-GJS-400-18-LT, DN 100-150, PN 25, fluids G2, L2, L1 DIN EN, body, 1.0619, DN 100-250, PN 16, all fluids Revision 00 Classification: Public · SAMSON AKTIENGESELLSCHAFT · Weismuellerstrasse 3 · 60314 Frankfurt am Main, Germany Page 2 of 3 EB 2512 EN...
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Norbert Tollas i.V. Peter Scheermesser Senior Vice President Director Global Operations Product Maintenance & Engineered Products Revision 00 Classification: Public · SAMSON AKTIENGESELLSCHAFT · Weismuellerstrasse 3 · 60314 Frankfurt am Main, Germany Page 3 of 3 14-4 EB 2512 EN...
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November 2022 Norbert Tollas Peter Scheermesser Senior Vice President Director Global Operations Product Maintenance & Engineered Products Revision 00 Classification: Public · SAMSON AKTIENGESELLSCHAFT · Weismüllerstrasse 3 · 60314 Frankfurt am Main, Germany Page 1 of 1 EB 2512 EN 14-7...
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November 2022 Norbert Tollas Peter Scheermesser Senior Vice President Director Global Operations Product Maintenance & Engineered Products Revision 00 Classification: Public · SAMSON AKTIENGESELLSCHAFT · Weismüllerstrasse 3 · 60314 Frankfurt am Main, Germany Page 1 of 1 14-8 EB 2512 EN...
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Frankfurt am Main, 27 April 2022 Norbert Tollas Peter Scheermesser Senior Vice President Director Global Operations Product Maintenance & Engineered Products Revision 00 Classification: Public · SAMSON AKTIENGESELLSCHAFT · Weismuellerstrasse 3 · 60314 Frankfurt am Main, Germany Page 1 of 1 EB 2512 EN 14-9...
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Frankfurt am Main, 27 April 2022 Stephan Giesen Peter Scheermesser Director Director Product Management Product Maintenance & Engineered Products Revision 00 Classification: Public · SAMSON AKTIENGESELLSCHAFT · Weismuellerstrasse 3 · 60314 Frankfurt am Main, Germany Page 1 of 1 14-10 EB 2512 EN...
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Frankfurt am Main, 27 April 2022 Stephan Giesen Peter Scheermesser Director Director Product Management Product Maintenance & Engineered Products Revision 00 Classification: Public · SAMSON AKTIENGESELLSCHAFT · Weismuellerstrasse 3 · 60314 Frankfurt am Main, Germany Page 1 of 1 EB 2512 EN 14-11...
40 to 640 cm² Control line connection (16) – 40 to 640 cm² 15.2 Lubricants 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. ∙ Item number Compensation Type 2413 Actuator...
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...
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EB 2512 EN EB 2512 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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