eb 2512 en - samson · eb 2512 en 1-1 safety instructions and measures 1 safety instructions and...

Translation of original instructions

EB 2512 EN

Type 41-23 Universal Pressure Reducing ValveSelf-operated Pressure Regulators

Edition June 2020

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.

Î For the safe and proper use of these instructions, read them carefully and keep them for later reference.

Î If you have any questions about these instructions, contact SAMSON‘s After-sales Service Department ([email protected]).

The mounting and operating instructions for the devices are included in the scope of delivery. The latest documentation is available on our website at www.samson.de > Service & Support > Downloads > Documentation.

Definition of signal words

Hazardous situations which, if not avoided, will result in death or serious injury

Hazardous situations which, if not avoided, could result in death or serious injury

Property damage message or malfunction

Additional information

Recommended action

DANGER!

WARNING!

NOTICE!

Note

Tip

2 EB 2512 EN

Contents

EB 2512 EN

1 Safety instructions and measures ................................................................1-11.1 Notes on possible severe personal injury ......................................................1-41.2 Notes on possible personal injury ................................................................1-51.3 Notes on possible property damage .............................................................1-61.4 Warnings on the regulator ...........................................................................1-92 Markings on the device ..............................................................................2-12.1 Nameplates ................................................................................................2-12.2 Locations of the nameplate ..........................................................................2-22.3 Material numbers ........................................................................................2-22.3.1 Type 2412 Valve .........................................................................................2-22.3.2 Type 2413Actuator ....................................................................................2-23 Design and principle of operation ...............................................................3-13.1 Additionalfittings ........................................................................................3-33.2 Technical data ............................................................................................3-44 Shipment and on-site transport ...................................................................4-14.1 Accepting the delivered goods .....................................................................4-14.2 Removing the packaging from the valve and actuator ....................................4-14.3 Transporting and lifting the regulator ............................................................4-24.3.1 Transporting the regulator ............................................................................4-24.3.2 Lifting the regulator .....................................................................................4-34.4 Storing the valve .........................................................................................4-45 Installation .................................................................................................5-15.1 Installation conditions ..................................................................................5-15.2 Preparation for installation ...........................................................................5-45.3 Assembly ...................................................................................................5-65.3.1 Installing the regulator .................................................................................5-65.3.2 Cleaning the pipeline ..................................................................................5-75.4 Testing the regulator ....................................................................................5-85.4.1 Leak test .....................................................................................................5-95.4.2 Pressure test ................................................................................................5-95.5 Insulation .................................................................................................5-106 Start-up .....................................................................................................6-1

Contents

EB 2512 EN

6.1 Starting up the plant ....................................................................................6-26.1.1 Regulation of liquids ....................................................................................6-26.1.2 Regulation of steam .....................................................................................6-27 Operation ..................................................................................................7-17.1 Adjusting the set point .................................................................................7-18 Malfunctions ..............................................................................................8-18.1 Troubleshooting ..........................................................................................8-18.2 Emergency action .......................................................................................8-39 Servicing....................................................................................................9-19.1 Preparing the valve for service work .............................................................9-49.2 Installing the regulator after service work ......................................................9-49.3 Service work...............................................................................................9-49.3.1 Replacing the actuator .................................................................................9-59.3.2 Replacing the set point springs .....................................................................9-69.3.3 Replacing the seat and plug .........................................................................9-79.3.4 Replacing the operating diaphragm .............................................................9-79.4 Ordering spare parts and operating supplies ................................................9-810 Decommissioning .....................................................................................10-111 Removal ..................................................................................................11-111.1 Removing the valve from the pipeline ..........................................................11-111.2 Removing the actuator from the valve .........................................................11-112 Repairs ....................................................................................................12-112.1 Returning devices to SAMSON ..................................................................12-113 Disposal ...................................................................................................13-114 Certificates ...............................................................................................14-115 Annex......................................................................................................15-115.1 Tightening torques .....................................................................................15-115.2 Lubricant ..................................................................................................15-115.3 Tools ........................................................................................................15-115.4 Accessories ..............................................................................................15-115.5 Spare parts ..............................................................................................15-215.6 After-sales service .....................................................................................15-4

EB 2512 EN 1-1

Safety instructions and measures

1 Safety instructions and measuresIntended useTheSAMSONType 41-23Regulatorisapressureregulator.ItconsistsofaType 2412ValveandaType 2413Actuator.Thevalveandactuator(exceptfortestedregulators)aredeliv-ered separately and must be assembled together according to these instructions.The self-operated regulator is used to control the downstream pressure p2 in the pipeline to the adjusted set point. Liquids, gases and vapors in processing and industrial plants can be controlled by the regulator.Theregulatorsaredesignedtooperateunderexactlydefinedconditions(e.g.operatingpres-sure, process medium, temperature). Therefore, operators must ensure that the regulators are onlyusedinoperatingconditionsthatmeetthespecificationsusedforsizingthedevicesatthe ordering stage. In case operators intend to use the regulators in other applications or conditionsthanspecified,contactSAMSON.SAMSON does not assume any liability for damage resulting from the failure to use the de-viceforitsintendedpurposeorfordamagecausedbyexternalforcesoranyotherexternalfactors.

Î Refertothetechnicaldataandnameplateforlimitsandfieldsofapplicationaswellaspossible uses.

Reasonably foreseeable misuseThe regulators are not suitable for the following applications: − Useoutsidethelimitsdefinedduringsizingandbythetechnicaldata − Useoutsidethelimitsdefinedbytheadditionalfittingsmountedontheregulator

Furthermore, the following activities do not comply with the intended use: − Use of non-original spare parts − Performing service and repair work not described in these instructions

QualificationsofoperatingpersonnelThe regulator must be mounted, started up, serviced and repaired by fully trained and quali-fiedpersonnelonly;theacceptedindustrycodesandpracticesaretobeobserved.Accord-ing to these mounting and operating instructions, trained personnel refers to individuals who areabletojudgetheworktheyareassignedtoandrecognizepossiblehazardsduetotheirspecializedtraining,theirknowledgeandexperienceaswellastheirknowledgeoftheappli-cable standards.

1-2 EB 2512 EN


Personal protective equipmentWerecommendcheckingthehazardsposedbytheprocessmediumbeingused(e.g.u GESTIS(CLP)hazardoussubstancedatabase).Dependingontheprocessmediumand/orthe activity, the protective equipment required includes: − Protectiveclothing,safetyglovesandeyeprotectioninapplicationswithhot,coldand/or

corrosive media − Wear hearing protection when working near the valve − Hard hat − Safety harness when working at height − Safety footwear, ESD (electrostatic discharge) footwear, if necessary Î Check with the plant operator for details on further protective equipment.

RevisionsandothermodificationsRevisions,conversionsorothermodificationsoftheproductarenotauthorizedbySAMSON.Theyareperformedattheuser'sownriskandmayleadtosafetyhazards,forexample.Fur-thermore, the product may no longer meet the requirements for its intended use.

Warning against residual hazardsTo avoid personal injury or property damage, plant operators and operating personnel must preventhazardsthatcouldbecausedintheregulatorbytheprocessmedium,theoperatingpressureorbymovingpartsbytakingappropriateprecautions.Theymustobserveallhaz-ard statements, warning and caution notes in these mounting and operating instructions.Hazardsresultingfromthespecialworkingconditionsattheinstallationsiteoftheregulatormustbeidentifiedinariskassessmentandpreventedthroughthecorrespondingsafetyin-structions drawn up by the operator.Wealsorecommendcheckingthehazardsposedbytheprocessmediumbeingused(e.g.u GESTIS(CLP)hazardoussubstancedatabase).

Î Observesafetymeasuresforhandlingthedeviceaswellasfirepreventionandexplosionprotection measures.

Safety featuresTheType 41-23Regulatordoesnothaveanyspecialsafetyfeatures.Whenrelievedofpres-sure, the regulator is opened by the force of the set point springs.

http://www.dguv.de/ifa/gestis/gestis-stoffdatenbank/index-2.jsp

http://www.dguv.de/ifa/gestis/gestis-stoffdatenbank/index-2.jsp

EB 2512 EN 1-3


Responsibilities of the operatorThe 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,theoperatormustensurethatoperatingpersonnelorthirdpersonsarenotex-posed to any danger.Theoperatorisadditionallyresponsibleforensuringthatthelimitsfortheproductdefinedinthe technical data are observed. This also applies to the start-up and shutdown procedures. 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 processes since the operative details (e.g. differential pressures and temperatures) vary in each individual case and are only known to the operator.

Responsibilities of operating personnelOperating personnel must read and understand these mounting and operating instructions as wellasthereferenceddocumentsandobservethespecifiedhazardstatements,warningsand caution notes. Furthermore, the operating personnel must be familiar with the applicable health, safety and accident prevention regulations and comply with them.

Referenced standards and regulationsThe regulators comply with the requirements of the European Pressure Equipment Directive 2014/68/EU.RegulatorswithaCEmarkinghaveanEUdeclarationofconformity,whichincludes information about the applied conformity assessment procedure. This EU declaration ofconformityisincludedinthe'Certificates'section.AccordingtotheignitionriskassessmentperformedinaccordancewithEN 13463-1:2009,section 5.2, the non-electrical regulators do not have their own potential ignition source even in the rare incident of an operating fault. As a result, they do not fall within the scope of Directive 2014/34/EU.

Î Forconnectiontotheequipotentialbondingsystem,observetherequirementsspecifiedinsection6.4ofEN 60079-14(VDE 0165Part1).

1-4 EB 2512 EN


Referenced documentationThe following documents apply in addition to these mounting and operating instructions: − Mounting and operating instructions for

e.g. Acccessories: Compensation chamber u EB 2595

e.g. Type 2 NIStrainer u EB 1015

− Data sheets for

e.g. Accessories:Compensationchamber · Screwfittings · Controllineconnection · Controlline u T 2595

e.g. Type 2 NIStrainer u T 1015

− Mountingandoperatinginstructionsaswellasdatasheetsforadditionalfittings(e.g. shut-off valves, pressure gauges etc.).

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 Observethemaximumpermissiblepressureforregulatorandplant. Î Beforestartinganyworkontheregulator,depressurizeallplantsectionsaffectedas well as the regulator.

Î Drain the process medium from all the plant sections affected as well as the regula-tor.

https://www.samson.de/document/e25950en.pdf


https://www.samson.de/document/t25950en.pdf


EB 2512 EN 1-5


1.2 Notes on possible personal injury

WARNING!

Crush hazard arising from moving parts.Theregulatorcontainsmovingparts(setpointsprings),whichcaninjurehandsorfin-gers if inserted into the regulator.

Î Donotinserthandsorfingersbetweenthesetpointspringswhiletheregulatorisin operation.

Î Donotinserthandsorfingersbetweenthepillarsandsetpointspringswhiletheregulator is in operation.

Î Donotinserthandsorfingersbetweenthespringplateandcrossbeamwhiletheregulator is in operation.

Î Beforeperforminganyworkontheregulator,depressurizetheplant.Disconnectorshut off the control line.

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 withdirtorbecomeillegibleinsomeotherway.Asaresult,hazardsmaygounno-ticed and the necessary instructions not followed. There is a risk of personal injury.

Î Keep all relevant markings and inscriptions on the device in a constantly legible state.

Î Immediately renew damaged, missing or incorrect nameplates or labels.

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.

Risk of burn injuries due to hot or cold components and pipelines.Depending on the process medium, regulator components and pipelines may get very hot or cold and cause burn injuries.

Î Allow components and pipelines to cool down or heat up. Î Wear protective clothing and safety gloves.

1-6 EB 2512 EN


WARNING!

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.

Î Information on safe use of the part affected u http://www.samson.de/reach-en.html.

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 injury, e.g. (chemical) burns.

Î If possible, drain the process medium from all the plant sections affected and the regulator.

Î Wear protective clothing, safety gloves and eye protection.

Risk of personal injury due to loaded springs.The set point springs of regulators with adjusted set point are preloaded and are under tension.

Î Beforestartinganyworkonthesprings,relievethecompressionfromthepreload-ed springs.

1.3 Notes on possible property damage

NOTICE!

Risk of regulator damage due to incorrectly attached slings. Î Do not attach load-bearing slings to the actuator housing.

www.samson.de/reach-en.html

www.samson.de/reach-en.html

EB 2512 EN 1-7


NOTICE!

Risk of regulator damage due to unsuitable medium properties.Theregulatorisdesignedforaprocessmediumwithdefinedproperties.

Î Onlyusetheprocessmediumspecifiedforsizing.

Risk of regulator damage due to contamination (e.g. solid particles) in the pipeline.The plant operator is responsible for cleaning the pipelines in the plant.

Î Flush the pipelines before start-up.

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 the surface.

Î Only use lubricants approved by SAMSON. When in doubt, consult SAMSON.

Riskofleakageandregulatordamageduetoexcessivelyhighorlowtighteningtorques.Observethespecifiedtorquesontighteningregulatorcomponents.Excessivelytight-ened torques lead to parts wearing out quicker. Parts that are too loose may cause leakage.

Î Observethespecifiedtighteningtorques(seeAnnex).

Risk of regulator damage due to the use of unsuitable tools.Certain tools are required to work on the regulator.

Î Only use tools approved by SAMSON. When in doubt, consult SAMSON.

Risk of contamination of the process medium through the use of unsuitable lubricant and/or contaminated tools and components.

Î Keep the regulator and the tools used free from solvents and grease. Î Make sure that only suitable lubricants are used.

1-8 EB 2512 EN


NOTICE!

Risk of excess pressure damaging plant sections due to construction-related seat leakage through the regulator.

Î Alwaysfitasafetydevice(e.g.safetyexcesspressurevalveorsafetyreliefvalve)inthe plant.

Incorrect control due to the formation of ice on the regulator.Mediumtemperaturesbelow0 °Cmaycauseicetoformontheregulator,dependingon the air humidity. This may affect, in particular, the functioning of the plug or dia-phragm stem guide.

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.

SAMSON's After-sales Service can support you concerning lubricant, tightening torques and tools approved by SAMSON.

Note

EB 2512 EN 1-9


1.4 Warnings on the regulatorWarning Meaningofthewarning Location on the device

Attention ! Do not

disassemble the valve without relieving the

tension from the set point spring.

Warning to indicate that the set point springs are loaded.There is a risk of serious head or face injury through the sudden release of the set point springs while unscrewing the crossbeam when the set point springs are loaded.

Completely relieve the tension from

the set point springs before

unthreading the two nuts.

Warning to indicate that the set point springs are loaded.Thereisariskofinjurytohandsorfingersthroughthesudden release of the actuator stem if they are inserted betweenthecrossbeamandsetpointspringswhileex-changing the actuator.

Unlock/unlocktheplug stem

Warningtoindicatepropertydamageatthebellowsseal.There is a risk of damage to the bellows seal due to the incorrect mounting or removal of the plug stem.

1-10 EB 2512 EN


EB 2512 EN 2-1

Markings on the device

2 Markings on the deviceSeveralnameplatesareaffixedtothedevice.Thenameplatesareusedtoidentifythesepara-teregulatorcomponents(seeFig. 2-1).

2.1 Nameplates

Valve nameplate

DIN version ANSI version2 3 1 4 5

11109876

2 3 1 4 5

11109876

ANSIversion·DINversion1 Valve type2 Modelnumberwithindex3 ConfigurationID4 Order number or date

5 KVS/CV

6 Set point range or spring range7 Valvesize8 Pressure rating

9 Perm. differential pressure10 Perm. temperature11 Bodymaterial

Actuator nameplate

DIN/ANSI version1 Actuatorarea(DIN/ANSI)2 Actuator type designation2.1 Valve type designation3 ConfigurationID4 ID number5 YearofCEcertification

6.2Max.perm.pressureattheactuator,basedonthemax.adjustablesetpoint(DIN/ANSI)

7 Valvesize(DIN/ANSI)

9 Setpointrange(DIN/ANSI)10 Diaphragm material11 CE mark12 Numberofcertificationbody

DIN/ANSIversion

6.2

2 2.1 3 4 1 11 5

9 7 910 12

Fig. 2-1: Nameplates of regulator parts

2-2 EB 2512 EN

Markings on the device

2.2 Locations of the nameplate

Location of the nameplate on the

regulator components

Fig. 2-2: Nameplate of the Type 2412 Valve and on the Type 2413 Actuator (diaphragm or bellows)

2.3 Material numbers

2.3.1 Type 2412 ValveSeethenameplate(11,ANSI/DINbodyma-terial). For more details on the nameplate, seesection 2.1.

2.3.2 Type 2413ActuatorSpecifyingtheconfigurationID,youcancon-tactustofindoutwhichmaterialisused.TheconfigurationIDisspecifiedonthenamepla-te(3,ANSI/DINconfigurationID).Formoredetailsonthenameplate,seesection 2.1.

EB 2512 EN 3-1

Design and principle of operation

3 Design and principle of oper-ation

Î RefertoFig. 3-1The Type 41-23 Pressure Reducing Valve consistsofaType 2412ClosingValveandaType 2413Actuator.Thevalveandactuator(exceptfortestedregulators)aredeliveredseparately and must be assembled together according to these instructions (see the 'In-stallation' section).The pressure reducing valve is used to main-tain the pressure downstream of the valve to an adjusted set point.Theprocessmediumflowsthroughthevalvebetween seat (2) and plug (3) in the direc-tion indicated by the arrow on the body. The position of the valve plug determines the flowrateand,asaresult,thepressureratioacross the valve. The plug stem is sealed by a frictionless bellows (5.1). The downstream pressure p2 is transmitted over the compen-sation chamber (18) (for liquids above 150 °Candforsteam)andthecontrolline(17) to the operating diaphragm (12) (oper-ating bellows (12.1) in the version with bel-lows actuator) where it is converted into a positioning force. This force is used to move the valve plug depending on the force of the set point springs (7). The spring force is ad-justable at the set point adjuster (6). The valves with KVS 4andhigherhaveabalanc-ing bellows (4). The upstream pressure acts on the outside of the bellows and the down-stream pressure on the inside of the bellows. As a result, the forces produced by the up-stream and downstream pressures acting on the plug are balanced out.

Depending on the valve and actuator used, the regulator can be upgraded to create a pressurereducingvalveforlowflowrates,asteam pressure reducing valve or a pressure reducing valve with increased safety (actua-tor with two diaphragms).The valve closes when the downstream pres-sure rises.

LegendforFig. 3-1

1 Valve body2 Seat3 Plug4 Balancingbellows5 Plug stem5.1 Bellows6 Set point adjuster7 Set point springs7.1 Spring plate8 Crossbeam8.1 Pillar(viewdrawnturnedby90°)8.2 Nuts for pillars8.3 Tapped holes9 Fastening nuts10 Diaphragmactuator/bellowsactuator11 Actuator stem12 Operating diaphragm12.1 Operating bellows13 Diaphragm plate14 Diaphragm plate nut15 Nuts and bolts

16ControllineconnectionG ¼(with screw joint with restriction when used with steam)

17Control line (to be provided on site)(available as control line kit for direct pressure tapping at the body u T 2595)

18 Compensation chamber19 Filler plug20 Travel stop cap with cotter pin


3-2 EB 2512 EN


2

3

4

5

6

7

5.1

10

11

12 16

1819

17

1

89

15

20

13 14

8.2

8.1

8.2

p1 p2

7.1

Type 2412 Valve

Type 2413DiaphragmActuator

12.1

16

8.2

10

Bellowsactuator for DN 15to50

8.3

10

16

Bellowsactuator for DN 65to100

Type 2413BellowsActuatorfor2to6,5to10,10to22and20to28 bar

Fig. 3-1: Functional diagram for regulators, DN 32 to 100 with balancing bellows

EB 2512 EN 3-3


3.1 Additionalfittings Î RefertoFig. 3-2

StrainersWe recommend installing a SAMSON strainer (2) upstream of the valve. It prevents solid particles in the process medium from damaging the regulator.

Î Do not use the strainer to permanently filtertheprocessmedium.

Î Selectastrainer(meshsize)suitableforthe process medium.

Any impurities carried along by the process medium may impair the proper functioning of the regulator. We recommend installing a strainer (e.g. SAMSON Type 2 NI) upstream of the pressure reducing valve (u EB 1015).

Pressure gaugesInstall a pressure gauge (3 and 5) both up-stream and downstream of the regulator to monitor the pressures prevailing in the plant.

Note

Control line connection in pipeline:Controllineconnectionbelowthe

middleoftheflange:

1 42 18 5 63

184

Min. pipe diameter ½“

Control line connection in manifold: Connectionabovethemiddleoftheflange:

1 2 4

5

718

3

184H k

Hk = Additional condensate head

1 Shut-off valve2 Strainer3 Upstream pressure gauge

4 Pressure reducing valve

5 Downstream pressure gauge

6 Shut-off valve7 Steam trap18 Compensation chamber

Fig. 3-2: Sample application


3-4 EB 2512 EN


Bypass and shut-off valvesWe recommend installing a shut-off valve (1 and 6) both upstream of the strainer and downstream of the regulator and installing a bypass line. The bypass ensures that the plant does not need to be shut down for ser-vice and repair work on the regulator.

InsulationRegulators can be insulated to reduce heat energy transfer.Refer to the instructions in the 'Installation' section.

Noise emissionTrimswithflowdividerscanbeusedtore-duce noise emission (u T 2512).

The Type 41-23 Regulator is not a safety valve. If necessary, a suitable overpressure protection must be installed on site in the plant section.

3.2 Technical dataThe valve and actuator nameplates provide information on the valve and actuator ver-sions (see the 'Markings on the device' sec-tion).

More information is available in Data Sheet u T 2512.

Note

Note

ComplianceTheType 41-23RegulatorbearsboththeCEand EAC marks of conformity.

Process medium and scope of applicationTheType 41-23PressureReducingValveisused to maintain the pressure downstream of the regulator to an adjusted set point. − For liquids, gases and vapors − Max.temperature350 °C − Set points from 0.05to28 bar − ValvesizeDN 15to100 − Pressure ratings from PN 16to40

The regulator is open when relieved of pres-sure. The valve closes when the downstream pressure rises.

Temperature rangeDependingonhowtheregulatorisconfig-ured, it can be used up to temperatures of 350 °C(seeTable 3-1).Theminimumtem-perature is limited by the accessories used and the actuator's diaphragm material (u T 2595).

Leakage classThe metal-seated regulator has the leakage classIaccordingtoIEC 60534-4.The soft-seated regulator has the leakage classIVaccordingtoIEC 60534-4.


https://www.samson.de/document/t25120de.pdf


EB 2512 EN 3-5


Table 3-1: Technical data · All pressures in bar (gauge)Valve Type 2412

Valvesize DN 15to50 DN 65to80 DN 100Pressure rating PN 16,25or40Max.permissibledifferentialpressure∆p 25 bar 20 bar 16 bar

Max.permissible temperature

Valve u T 2500 ∙ Pressure-temperaturediagram

Valve plug Metal seal: 350 °C · PTFEsoftseal:220 °CEPDM or FKM soft seal: 150 °C·NBRsoftseal:80 °C

Leakage class according to IEC 60534-4

Metalseal:leakageclassI(≤0.05 %ofKVScoefficient) Softseal:leakageclass IV(≤0.01 %ofKVScoefficient)

ComplianceDiaphragm actuator Type 2413

Actuator area cm² 640 320 160 80 40

Set point ranges bar 0.05 to 0.25 0.1 to 0.6 0.2 to 1.2 0.8 to 2.5 2) 2 to 5 4.5 to 10

8 to 16

Max.permissibletemperature

Gases350 °C,however,max.80 °Cattheactuator·Liquids150 °C, with compensation chamber 350 °C·Steamwithcompensation

chamber 350 °CBellowsactuator Type 2413

Actuator area cm² 33 62Set point ranges bar 10to22 · 20to28 2 to 6 1) · 5to10 barSet point spring 8000 N

1) Setpointspring4400 N2) Versionwithactuatorwithtwodiaphragms:1to2.5 bar

Noise emissionSAMSON is unable to make general state-ments about noise emission as it depends on the regulator version, plant facilities, process medium and operating conditions.

DimensionsandweightsTable 3-5providesasummaryofthedimen-sions and weights. The lengths and heights in the dimension diagrams are shown on page 3-10.

http://www.samson.de/pdf_en/t25000en.pdf

3-6 EB 2512 EN


Table 3-2:Max. permissible pressure at actuatorSet point ranges Max. perm. pressure above the set point adjusted at the actuator

Diap

hrag

m a

ctuat

or 0.05to0.25 bar · 0.1to0.6 bar 0.6 bar

0.2to1.2 bar 1.3 bar

0.8to2.5 bar 2.5 bar

2to5 bar 5 bar

4.5to10 bar · 8to16 bar 10 bar

Bellows

actu

ator 2to6 bar · 5to10 bar 6.5 bar

10to22 bar 8 bar

20to28 bar 2 bar

The maximum permissible pressure at the actuator depends on the currently adjusted set point. Add the value listed in the table to it.

Example:Set point range: 0.2to1.2 barSet point adjusted: 0.8 bar

Max. permissible pressure at the actuator: 0.8 bar + 1.3 bar = 2.1 bar

Table 3-3: KVS coefficients and xFZ values · Terms for noise level calculation according to VDMA 24422 (edition 1.89)Valve size DN 15 20 25 32 40 50 65 80 100

KVS 1) · Standardversion 4.0 6.3 8.0 16 20 32 50 80 125

xFZ 0.5 0.45 0.4 0.35

KVS 1) · Specialversion 1.0 1.0 · 4.0 4.0 · 8.0 32 2) 80

xFZ 0.6 0.5 0.45 0.4

KVS 1) · Withflowdivider 3.0 5.0 6.0 12 15 25 38 42 66

1) KVS≤4:valvewithoutbalancingbellows2) Max.permissible∆p:25 bar

Note

EB 2512 EN 3-7


Table 3-4:Materials · Material numbers according to DIN ENValve Type 2412

Pressure rating PN 16 PN 25 PN 40

Max.permissibletemperature 300 °C 350 °C

Housing Cast iron EN-GJL-250

Spheroidal graph-ite iron

EN-GJS-400-18-LT

Cast steel 1.0619

Stainless steel 1.4408

Seat CrNi steel CrNiMo steel

PlugMaterial CrNi steel CrNiMo steel

Seal PTFEwith15 %glassfiber·EPDM·NBR·FKM

Guidebushing CrNi steel

Balancingbellowsandbellowsseal Stainless steel 1.4571

Actuator Type 2413

Diaphragm actuator Bellowsactuator

Diaphragm cases SheetsteelS235JR(St37-2) 1) –

Diaphragm EPDM · FKM· NBR · EPDMwithPTFE protective facing –

Bellowshousing – 1.5415/1.4301(stainlesssteelonly)

Bellows – 1.45711) In corrosion-resistant version (CrNi steel)

Table 3-5: Dimensions in mm and weights in kgPressure reducing valve Type 41-23

Valve size DN 15 DN 20 DN 25 DN 32 DN 40 DN 50 DN 65 DN 80 DN 100

Length L 130 150 160 180 200 230 290 310 350

Height H1 335 390 510 525

Height H2Forged steel 53 – 70 – 92 98 – 128 –

Other materials 44 72 98 1181) +10 %forallothermaterials2) Actuatorwithtwodiaphragms:1to2.5 bar3) Actuatorwithtwodiaphragms:HeightH+50 mm

3-8 EB 2512 EN




Standard versionwithType 2413DiaphragmActuator

Set p

oint

rang

es

0.05 to 0.25 bar

Height H 3) 445 500 627 650

Actuator ØD = 380 mm,A = 640 cm²

Valve spring force F 1750 N

0.1 to 0.6 bar

Height H 3) 445 500 627 650



0.2 to 1.2 bar

Height H 3) 430 480 607 635



0.8 to 2.5 bar 2)

Height H 3) 430 485 612 635



2 to 5 bar

Height H 3) 410 465 592 615



4.5 to 10 bar

Height H 3) 410 465 592 615



8 to 16 bar

Height H 3) 410 465 592 615



WeightforversionwithType 2413DiaphragmActuator

Set p

oint

rang

es

0.05 to 0.6 bar

Weight, based on castiron 1), approx.kg

22.5 23.5 29.5 31.5 35 51 58 67

0.2 to 2.5 bar 16 18 23.5 25.5 29 45 52 61

2 to 16 bar 12 13 18.5 21 24 40 47 56

1) +10 %forallothermaterials2) Actuatorwithtwodiaphragms:1to2.5 bar3) Actuatorwithtwodiaphragms:HeightH+50 mm

EB 2512 EN 3-9




VersionwithType 2413BellowsActuator

Set p

oint

rang

es

2 to 6 bar

Height H 550 605 732 755

Actuator ØD=120 mm,A=62 cm²


5 to 10 bar

Height H 550 605 732 755



10 to 22 bar

Height H 535 590 717 740



20 to 28 bar

Height H 535 590 717 740



Weight for version with bellows actuator

Set p

oint

rang

es 2 to 10 bar Weight, based on

castiron 1), approx.kg

16.5 17.9 18 23.5 25.5 29 48 56 66

10 to 28 bar 20.9 21.5 22 27.5 29.5 33 54 65 75

1) +10 %forallothermaterials2) Actuatorwithtwodiaphragms:1to2.5 bar3) Actuatorwithtwodiaphragms:HeightH+50 mm

3-10 EB 2512 EN


Dimensionaldrawings

H

H1

H2

L

ØD

H

H1

H2

L

ØD

Type 41-23withdiaphragmactuator Type 41-23withbellowsactuator

Fig. 3-3: Dimensions

EB 2512 EN 4-1

Shipment and on-site transport

4 Shipment and on-site trans-port

The work described in this section is only to beperformedbypersonnelqualifiedfortheassignment accordingly.

4.1 Accepting the delivered goods

After receiving the shipment, proceed as fol-lows:1. Check the scope of delivery. Check that

thespecificationsonthevalveandactua-tornameplatematchthespecificationsinthe delivery note. See the 'Markings on the device' section for nameplate details.

2. Check the shipment for transportation damage. Report any damage to SAMSON and the forwarding agent (re-fer to delivery note).

3. Determine the weight and dimensions of the units to be lifted and transported in order to select the appropriate lifting equipment and lifting accessories. Refer to the transport documents and the 'De-sign and principle of operation' section.

4.2 Removing the packaging from the valve and actu-ator

The components (valve, actuator and, if ap-plicable, control line) of the regulator are de-livered separately. A tested regulator is de-livered as an assembled unit.Proceed as follows to lift and install the valve:

Î Do not open or remove the packaging until immediately before lifting to install the valve into the pipeline.

Î Leave the regulator components in its transport container or on the pallet to transport it on site.

Î Do not remove the protective caps from the inlet and outlet until immediately be-fore installing the valve into the pipeline. They prevent foreign particles from enter-ing the valve.

Î Dispose and recycle the packaging in ac-cordance with the local regulations.

4-2 EB 2512 EN


4.3 Transporting and lifting the regulator

Risk due to suspended loads falling. Î Stay clear of suspended or moving loads.

Î Close off and secure the transport paths.

Risk of lifting equipment tipping over and risk of damage to lifting accessories due to exceeding the rated lifting capacity.

Î Only use approved lifting equipment and accessories whose minimum lifting ca-pacity is higher than the weight of the valve (including actuator and packaging, if applicable).

Î Refer to the 'Design and principle of op-eration' section for the weights.

Risk of injury due to incorrect lifting without the use of lifting equipment.Lifting the regulator without the use of lifting equipment may lead to injuries (back injury in particular) depending on the weight of the regulator.

Î Observe the guideline weight for manual handling: 15 to max. 55 kg taking into account age, gender and physical fitness

Î Observe the occupational health and safety regulations valid in the country of use.

DANGER!

WARNING!

WARNING!

Risk of personal injury due to the regulator tipping.

Î Observe the regulator's center of gravity. Î Secure the regulator against tipping over or turning.

Our after-sales service can provide more de-tailed transport and lifting instructions on re-quest.

4.3.1 Transporting the regu-lator

The regulator can be transported using lifting equipment (e.g. crane or forklift).

Î Leave the regulator in its transport con-tainer or on the pallet to transport it.

Î Observe the transport instructions.

Transport instructions Î Protecttheregulatoragainstexternalin-fluences(e.g.impact).

Î Do not damage the corrosion protection (paint, surface coatings). Repair any damage immediately.

Î Protect the piping and any mounted valve accessories against damage.

Î Protect the regulator against moisture and dirt.

Î The permissible ambient temperature of standardregulatorsis–20to+80 °C.

WARNING!

Tip

EB 2512 EN 4-3


4.3.2 Lifting the regulatorTo install a large regulator into the pipeline, use lifting equipment (e.g. crane or forklift) to lift it.

Lifting instructions Î Use a hook with safety latch to secure the slings from slipping during lifting and transporting(seeFig. 4-1).

Î Secure slings against slipping. Î Make sure the slings can be removed af-ter installation.

Î Prevent the regulator from tilting or tip-ping over.

Î Do not leave loads suspended when in-terrupting work for longer periods of time.

Î Makesurethattheaxisofthepipelineisalwayshorizontalduringliftingandtheaxisoftheplugstemisalwaysvertical.

Lifting1. Attachoneslingtotheflangeofthe

body and to the rigging equipment (e.g. hook) of the crane or forklift (see Fig. 4-1).

2. Carefully lift the regulator. Check wheth-er the lifting equipment and accessories can bear the weight.

3. Move the regulator at an even pace to the site of installation.

4. Install the regulator into the pipeline (see the 'Installation' section).

5. After installation in the pipeline, check whethertheregulatorflangesareboltedtight.

6. Remove slings.

Fig. 4-1: Schematic drawing of lifting points on the regulator

4-4 EB 2512 EN


4.4 Storing the valve

Risk of regulator damage due to improper storage.

Î Observe the storage instructions. Î Avoid long storage times. Î Contact SAMSON in case of different storage conditions or long storage peri-ods.

We recommend regularly checking the regu-lator and the prevailing storage conditions during long storage periods.

Storage instructions Î Protecttheregulatoragainstexternalin-fluences(e.g.impact).

Î Secure the regulator in the stored posi-tion against slipping or tipping over.

Î Do not damage the corrosion protection (paint, surface coatings). Repair any damage immediately.

Î Protect the regulator against moisture and dirt. Store it at a relative humidity of lessthan75 %.Indampspaces,preventcondensation. If necessary, use a drying agent or heating.

Î Make sure that the ambient air is free of acids or other corrosive media.

Î The permissible storage temperature of standardregulatorsis–20to+65 °C.

NOTICE!

Note

Î Do not place any objects on the regula-tor.

Special storage instructions for elastomersElastomer, e.g. operating diaphragm

Î To keep elastomers in shape and to pre-vent cracking, do not bend them or hang them up.

Î Store elastomers away from lubricants, chemicals, solutions and fuels.

− We recommend a storage temperature of 15 °Cforelastomers.

SAMSON's After-sales Service can provide more detailed storage instructions on re-quest.

Tip

EB 2512 EN 5-1

Installation

5 InstallationThe work described in this section is only to beperformedbypersonnelqualifiedfortheassignment accordingly.

5.1 Installation conditionsWork positionThe work position for the regulator is the front view onto all operating controls on the regulator(includinganyadditionalfittings)seen from the position of operating person-nel.Plant operators must ensure that, after instal-lation of the device, the operating personnel can perform all necessary work safely and easily access the device from the work posi-tion.

Pipeline routingThe inlet and outlet lengths vary depending on the process medium. To ensure that the regulator functions properly, proceed as fol-lows:

Î Observe the inlet and outlet lengths (see Table 5-6).ContactSAMSONifthereg-ulator conditions or state of the medium process deviate.

Î Install the regulator free of stress and with the least amount of vibrations as possible. Read information under ‘Mounting position’ and ‘Support or sus-pension’ in this section.

Î For media with a tendency to conden-sate, install the pipeline with a slight downward slope on both sides so that the condensate can drain properly. If the pipeline upstream and downstream of the regulator run vertically upwards, an automatic water drainage is required.

Î Installtheregulatorallowingsufficientspace to remove the actuator and valve or to perform service work on them.

Mounting positionTo ensure that the regulator functions proper-ly, proceed as follows:

Î Install the actuator housing with the set point springs suspended downward in horizontalpipelines(seeFig. 5-1).

Î Makesurethedirectionofflowmatchesthe direction indicated by the arrow on the body.

Î Contact SAMSON if the mounting posi-tionisnotasspecifiedabove.

Damage due to freezing.Protect the regulator from icing up when con-trolling media that can freeze. Remove the regulator from the pipeline when the plant is shut down if the regulator is not installed ar-eas free from frost.

NOTICE!

5-2 EB 2512 EN

Installation

Support or suspension

The plant engineering company is responsi-ble for selecting and implementing a suitable support or suspension of the installed regula-tor and the pipeline.

Depending on the regulator version and mounting position, the valve, actuator and pipeline must be supported or suspended.

Do not attach supports directly to the valve or actuator.

Control lineThe control line must be provided at the site of installation, e.g. a 3/8“ pipe for steam or an8x1or6x1 mmpipeforair/water.Connect the control line to the downstream line (p2) at least one meter away from the valve outlet.Weld the control line at the side in the mid-dle of the pipe, inclining at a ratio of ap-proximately1:10uptothecompensationchamber. If a manifold is located down-stream of the pressure reducing valve, con-nect the valve to the manifold, even if it is severalmetersaway(seeTable 5-6andFig. 5-2).

Control line kitA control line kit for tapping pressure at the valve body is available as an accessory part from SAMSON.

Note

NOTICE!

Do not install any instruments (e.g. tempera-ture regulators or shut-off valves) that restrict the cross-section of the pipe between the pressure tapping point and the regulator.

Standard mounting positionFor gases, liquids and steam

Alternative mounting position for gases and liquids at medi-um temperature upto80 °C.Not for steam.

Not permissible! 1)

Fig. 5-1: Mounting position

1) On request: Permissible for regulators with fixedplugstemguidepluswithmediumtemperatureupto80 °C.Notforsteam.

Note

EB 2512 EN 5-3

Installation

Correct!

Incorrect!

Connection at the top – incorrect position

Incorrect!

Connection at the side – optimal Connection at the bottom – incorrect position

Fig. 5-2: Control line connection, depending on how the pipeline is routed

If the control line connection is located below themiddleofthevalveinletflange,arrangethe compensation chamber at the same level astheinletflange.Inthiscase,useapipewhichisatleast½“insizeforthecontrolline from the tapping point to the compensa-tion chamber.If the control line is connected above the middleofthevalveinletflange,installthecompensation chamber at the same level as the upstream pressure tapping point. The ad-ditional pressure of the condensate head (Hk, Fig. 5-3)mustbecompensatedforbyadjust-ing the set point.

Needle valveIf the regulator tends to hunt, we recommend installing a needle valve at the control line connection (16) in addition to the standard SAMSON screw joint with restriction.

Compensation chamberA compensation chamber (18) is required forliquidsabove150 °Caswellasforsteam. The mounting position of the compen-sation chamber is indicated by an adhesive label on the chamber itself as well as by an arrow and the word "top" stamped on the top of the chamber.Thismountingpositionmustbeadheredto;otherwise the safe functioning of the regula-tor cannot be guaranteed.Weld the line coming from the pressure tap-ping point to the 3/8“ pipe socket on the chamber. Install the compensation chamber at the highest point of the pipeline. Consequently, the control line between compensation chamber and actuator must also be installed with a downward slope. In this case, use a 3/8“pipewithscrewfittings.

5-4 EB 2512 EN

Installation

5.2 Preparation for installationValve and actuator can be assembled before or after the valve has been installed in the pipeline.Werecommendfirstinstallingthevalve without the actuator into the pipeline.Beforeinstallation,makesurethefollowingconditions are met:

− The valve is clean. − The valve, actuator and all piping are

not damaged. − Install a strainer upstream of the regula-

tor. − The valve data on the nameplate (type designation,valvesize,material,pres-sure rating and temperature range) matchtheplantconditions(sizeandpressure rating of the pipeline, medium temperature etc.). See the 'Markings on the device' section for nameplate details.

− Therequestedorrequiredadditionalfit-tings (see the 'Design and principle of operation' section) have been installed or prepared as necessary before installing the valve.

Proceed as follows: Î Lay out the necessary material and tools to have them ready during installation work.

Î Flush the pipeline before installing the regulator.The plant operator is responsible for cleaning the pipelines in the plant.

Î For steam applications, dry the pipelines. Moisture will damage the inside of the regulator.

Î Check any mounted pressure gauges to make sure they function properly.

EB 2512 EN 5-5

Installation

Table 5-6: Inlet and outlet lengths

Control line (e.g. control line kit, see information under ‘Control line’)

DN

min.a x DN

min.b x DN

a Inlet lengthb Outlet length

State of process medium Valve conditions Inlet length a Outlet length b

Gas Ma ≤ 0.3 2 4Vapors 1) Ma ≤ 0.3 2 4

LiquidFreeofcavitation/w < 3 m/s 2 4Cavitationproducingnoise/w ≤ 3 m/s 2 4

1) No saturated steam

Connectionabovethemiddleoftheflange:

184

H k

Additional condensate head

4 Pressure reducing valve18 Compensation chamber

Fig. 5-3: Example of installation with steam

5-6 EB 2512 EN

Installation

5.3 AssemblyTested SAMSON regulators are delivered as an assembled unit. In all other cases, the separate components (valve, actuator and control line) of the regulator are delivered separately. Upon delivery, the separate com-ponents must be assembled together. Pro-ceed as follows to assemble the regulator and to prepare for start-up.

Risk of regulator damage due to exces-sively high or low tightening torques.Observe the specified torques on tightening regulator components. Excessively tightened torques lead to parts wearing out quicker. Parts that are too loose may cause leakage.

Î Observe the specified tightening torques (see Annex).

Risk of regulator damage due to the use of unsuitable tools.

Î Only use tools approved by SAMSON (see Annex).

Risk of regulator damage due to the use of unsuitable lubricants.

Î Only use lubricants approved by SAMSON (see Annex).

NOTICE!

NOTICE!

NOTICE!

5.3.1 Installing the regulator1. Close the shut-off valves upstream and

downstream of the regulator while the regulator is being installed.

2. Remove the protective caps from the valve ports before installing the valve.

3. Lift the valve using suitable lifting equip-ment to the site of installation. Observe theflowdirectionthroughthevalve.Thearrow on the valve indicates the direction offlow.

4. Makesurethatthecorrectflangegasketsare used.

5. Boltthepipetothevalvefreeofstress.6. Mount the actuator.

Î DiaphragmactuatorDN 15to100 − Insert the actuator stem (11) through the

hole in the crossbeam (8) into the travel stop cap with cotter pin (20) and fasten the actuator with the nuts (9). Observe thetighteningtorquesspecifiedintheAnnex.

Î BellowsactuatorDN 15to50 − Remove the crossbeam (8) from the

valve. − Insert the actuator stem (11) into the trav-

el stop cap with cotter pin (20). − Align pillars (8.1) and fasten the actua-

tor with the nuts (8.2). Observe the tight-eningtorquesspecifiedintheAnnex.

EB 2512 EN 5-7

Installation

Î BellowsactuatorDN 65to100 − Remove the crossbeam (8) from the

valve. − Unscrew the pillars (8.1). − Screw the pillars (8.1) into the threaded holes(8.3)oftheactuatorflangeasfaras they will go.

− Insert the actuator stem (11) into the trav-el stop cap with cotter pin (20).

− Fasten the pillars (8.1) with the nuts (8.2) ontothevalveflange.Observethetight-eningtorquesspecifiedintheAnnex.

7. Lock the cotter pin (20) on the travel stop cap.

8. Mount the control line (17) onto the valve and actuator. Observe the tightening torquesspecifiedintheAnnex.

Î With diaphragm actuators − For steam or liquidsabove150 °C in-stallthecompensationchamberandfillitwith the process medium. Observe the tighteningtorquesspecifiedintheAn-nex.

9. Slowly open the shut-off valves in the pipeline after the valve has been in-stalled.

5.3.2 Cleaning the pipelineWerecommendadditionallyflushingthepipeline with installed regulator before start-up.

Î Unscrew the control line (17) from the valve body.

Î SealthevalvebodywithG ¼stoppers(accessories: stopper 8323-0030 and seal 8412-0771).

Î Observethemeshsizeoftheupstreamstrainerforthemaximumparticlesize.Use strainers to suit the process medium.

Î Check the strainer for dirt each time the pipelineisflushedandcleanit,ifneces-sary.

If the regulator malfunctions due to clogging afterflushingthepipeline,proceedasde-scribed in the ‘Malfunctions’ section.

5-8 EB 2512 EN

Installation

5.4 Testing the regulator

Risk of bursting due to incorrect opening of pressurized equipment or components.Regulators and pipelines are pressure equip-ment that may burst when handled incor-rectly. Flying projectile fragments or the re-lease of compressed medium can cause seri-ous injury or even death.Before working on the regulator:

Î Depressurize all plant sections affected and the regulator.

Î Disconnect the control line. Î Drain the process medium from all the plant sections affected as well as the valve.

Re

Risk of personal injury due to process me-dium escaping under pressure.

Î First start up the regulator after mounting all parts.

Risk of hearing loss or deafness due to loud noise.Noise emission (e.g. cavitation or flashing) may occur during operation caused by the process medium and the operating condi-tions.

Î Wear hearing protection when working near the regulator.

DANGER!

DANGER!

WARNING!

Crush hazard arising from moving parts. Î Do not insert hands or fingers between the set point springs while the regulator is in operation.

Î Do not insert hands or fingers between the pillars and set point springs while the regulator is in operation.

Î Do not insert hands or fingers between the spring plate and crossbeam while the regulator is in operation.

Î Before starting any work on the regula-tor, depressurize plant sections as well as the regulator.

Risk of burn injuries due to hot or very cold components and pipelines.Depending on the process medium, valve components and pipelines may get very hot or cold and cause burn injuries.

Î Wear protective clothing and safety gloves.

SAMSON regulators are delivered ready for use. To test the regulator functioning before start-up or putting back the regulator into service, perform the following tests:

WARNING! WARNING!

WARNING!

EB 2512 EN 5-9

Installation

5.4.1 Leak testThe plant operator is responsible for per-forming the leak test and selecting the test method. The leak test must comply with the requirements of the national and internation-al standards that apply at the site of installa-tion.

Our after-sales service can support you to plan and perform a leak test for your plant.

1. Slowly open the shut-off valve installed upstream of the regulator.

2. Apply the required test pressure.3. Check the regulator for leakage to the at-

mosphere.4. Depressurizethepipelinesectionand

valve.5. Rework any parts that leak and repeat

the leak test.

5.4.2 Pressure test

The plant operator is responsible for performing the pressure test. SAMSON's After-sales Service can support you to plan and perform a pressure test for your plant.

Tip

Note

Risk of valve damage due to a sudden pres-sure increase and resulting high flow veloci-ties.

− Slowly open the shut-off valves.

During the pressure test, make sure the fol-lowing conditions are met:

Î Donotallowthepressuretoexceedthe1.5 times the pressure rating of the valve body.

Î The regulator must remain open.Therefore,setthemaximumsetpointtoensure that the regulator does not close. Alternatively, detach the control line and seal the opening at the valve body with a G ¼stopper(accessories:stopper8323-0030 and seal 8412-0771).

Î Make sure that the pressure rises simulta-neously upstream and downstream of the regulator to avoid damaging the balanc-ing bellows.

NOTICE!

5-10 EB 2512 EN

Installation

5.5 InsulationToinsulatecoldsystems,werecommendfirstfillingtheplantandcarefullyrinsingit.Theregulator must not yet be insulated at this stage.

Risk of regulator damage due to incorrect insulation.

Î Only insulate the regulator up to the ac-tuator for medium temperatures below 0 °C or above 220 °C.

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.

3. Insulate the regulator and pipes convey-ing the process medium using insulation material with a water vapor barrier. If a control line is to be routed through the insulation, special care must be taken with the sealing since slight changes in shape may occur. The insulation thick-ness depends on the medium tempera-tureandtheambientconditions.50 mmis a typical thickness.

NOTICE!

EB 2512 EN 6-1

Start-up

6 Start-upThe work described in this section is only to beperformedbypersonnelqualifiedfortheassignment accordingly.

Re

Risk of personal injury due to process me-dium escaping under pressure.

Î First start up the regulator after mounting all parts.

Risk of burn injuries due to hot or cold com-ponents and pipeline.Regulator components and the pipeline may become very hot or cold. Risk of burn inju-ries.

Î Allow components and pipelines to cool down or heat up.


Risk of personal injury due to pressurized components and process medium escaping under pressure.

Î Do not loosen the control line while the valve is pressurized.

Risk of hearing loss or deafness due to loud noise.Noise emission (e.g. cavitation or flashing) may occur during operation caused by the

DANGER!

WARNING!

WARNING!

WARNING!

process medium and the operating condi-tions.






Beforestart-uporputtingthevalvebackintooperation, make sure the following condi-tions are met:

− The regulator is properly installed into the pipeline (see the 'Installation' sec-tion).

− The leak and function tests have been completed successfully (see 'Testing the regulator').

− The prevailing conditions in the plant sectionaffectedmeettheregulatorsizingrequirements (see information under ‘In-tended use’ in the 'Safety instructions and measures' section).

WARNING!

6-2 EB 2512 EN

Start-up

Start-up/putting the valve back into opera-tion1. Dependingonthefieldofapplication,

allow the regulator to cool down or heat up to reach ambient temperature before start up.

2. Slowly open the shut-off valves in the pipeline. Slowly opening these valves prevents a sudden surge in pressure and resulting high velocities that can damage the valve.

3. Check the regulator to ensure it functions properly.

Beforestartinguptheplant,makesurethefollowing conditions are met:

− The control line is open and correctly connected.

6.1 Starting up the plant1. Open the shut-off valves slowly prefera-

bly starting from the upstream pressure side. Afterwards, open all the valves on the consumer side (downstream of the regulator).

2. Fill the plant slowly with the process me-dium. Avoid pressure surges.

3. Make sure that the pressure rises simulta-neously upstream and downstream of the regulator to avoid damaging the balanc-ing bellows.

6.1.1 Regulation of liquids Î To start up the pressure regulator, open shut-off valves slowly.

Î For liquid medium temperatures above 150 °C,firstfillthecompensationcham-ber with the process medium. Proceed as follows:

1. Unscrewfillerplugfromthecompensa-tion chamber.

2. Use the included plastic funnel or a jug to pour in the process medium until it startstooverflow.

3. Screwthefillerplugbackinandtightenit.

6.1.2 Regulation of steam1. Unscrewfillerplugfromthecompensa-

tion chamber.2. Use the included plastic funnel or a jug

topourinwateruntilitstartstooverflow.3. Screwthefillerplugbackinandtighten

it. − All pipes conveying the process medium

must be completely drained and dry. − Air and condensate must be allowed to

escape from the plant. − Allow time for the pipes and valves to

heat up.

EB 2512 EN 7-1EB 2512 7-1

Operation

7 OperationImmediately after completing start-up or placing the regulator back into operation (see the 'Start-up' section), the regulator is ready for use.








WARNING!

WARNING!

WARNING!





7.1 Adjusting the set point Î The required downstream pressure is set by turning the set point adjuster (6) using an open-end wrench:

− DN 15to50withwidthacrossflatsSW 19

− DN 65and100withwidthacrossflatsSW 24

− The set point of the stainless steel regula-tor must be adjusted using the rod in-cluded.

Î Turn the set point adjuster clockwise () to increase the pressure set point.

Î Turn the set point adjuster counterclock-wise () to reduce the pressure set point.

The pressure gauge located on the down-stream pressure side allows the adjusted set point to be monitored.

WARNING!

7-2 EB 2512

Operation

An initial adjustment of the set point can also be made by changing the spring tension un-tilthedistancex(seeFig. 7-1andTable 7-1)is reached.

Note that during initial set point adjustment only a rough set point adjustment is per-formed by turning the set point adjustment until the distance x is reached. The special properties of the process medium and plant are not taken into account in this case.Check the pressure at the pressure gauge downstream of the regulator for a precise set point adjustment.

X

Set point adjuster (6)

Fig. 7-1: Set point adjustment with dimension x

Note

Table 7-1: Set point adjustment · Dimension xSet point range Valve size DN

8to16 bar 15 to 25 32 to 50 65 to 100

Set p

oint 10 bar x=89 mm x=106 mm x=133 mm

12 bar x=97 mm x=117 mm x=150 mm

14 bar x=104 mm x=128 mm x=168 mm

4.5to10 bar

Set p

oint 5.9 bar x=85 mm x=100 mm x=131 mm

7.3 bar x=93 mm x=112 mm x=152 mm

8.6 bar x=101 mm x=123 mm x=172 mm

2to5 bar

Set p


3.5 bar x=92 mm x=110 mm x=170 mm

4.3 bar x=100 mm x=122 mm x=184 mm

0.8to2.5 bar

Set p


1.7 bar x=89 mm x=106 mm x=142 mm

2.1 bar x=99 mm x=121 mm x=167 mm

0.2 to 1.2 bar

Set p


0.70 bar x=83 mm x=98 mm x=127 mm

1.0 bar x=95 mm x=117 mm x=157 mm

0.1 to0.6 bar

Set p


0.35 bar x=83 mm x=98 mm x=127 mm

0.48 bar x=95 mm x=115 mm x=157 mm

0.05to0.25 bar

Set p


0.15 bar x=81 mm x=95 mm x=116 mm

0.20 bar x=91 mm x=110 mm x=139 mm

EB 2512 EN 8-1

Malfunctions

8 Malfunctions

8.1 TroubleshootingMalfunction Possible reasons Recommended action

Downstream pressure exceedstheadjustedset point.

Insufficientpressurepulsesontheoperating diaphragm

ÎConnect the control line on site for regulators withexternalcontrolline. ÎCleanthecontrollineandscrewfittings.

Foreign particles blocking the plug ÎRemove foreign particles. ÎWhen parts are damaged, contact SAMSON's After-sales Service.

Seat and plug are worn or leak. ÎWhen parts are damaged, contact SAMSON’s After-sales Service.

Control line blocked ÎCleanthecontrollineandscrewfittings.

Pressure tapped at the wrong place (regulatorwithexternalcontrolline)

ÎReconnect the control line at another point. ÎDo not connect the control line at pipe bends or necks.

Regulator or KVS/CVcoefficienttoolarge

ÎCheckthesizing. ÎChange KVS/CVcoefficient,ifnecessaryorinstalladifferentsizedregulator. ÎContact SAMSON's After-sales Service.

Compensation chamber in the wrong position or too small (with steam)

ÎReconnect compensation chamber at a different placeorreplaceit(seeAnnex).

Defective operating diaphragm ÎReplace damaged diaphragm.

Downstream pressure hunts

Regulator or KVS/CVcoefficienttoolarge

ÎCheckthesizing. ÎChange KVS/CVcoefficient,ifnecessaryorinstalladifferentsizedregulator. ÎContact SAMSON's After-sales Service.



The restriction in the control line for pressure tapping is too large or missing.

Î Install a restriction. Î Install a smaller restriction.

8-2 EB 2512 EN

Malfunctions

Malfunction Possible reasons Recommended action

Slow control responseRestriction in the screw joint of the actuator dirty or too small ÎClean screw joint or install larger screw joint.

Dirt in the control line ÎClean the control line.

Downstream pressure drops below the adjusted set point.

Regulatorinstalledagainsttheflow Î Installtheregulatorsothatthedirectionofflowmatches the direction indicated by the arrow on the body.

Regulator or KVS/CVcoefficienttoosmall

ÎCheckthesizing. ÎChange KVS/CVcoefficient,ifnecessaryorin-stalladifferentsizedregulator. ÎContact SAMSON's After-sales Service.



Foreign particles blocking the plug ÎRemove foreign particles. ÎWhen parts are damaged, contact SAMSON’s After-sales Service.

Compensation chamber in the wrong position or too small (with steam)

ÎReconnect compensation chamber at a different placeorreplaceit(seeAnnex).

Control line blocked ÎCleanthecontrollineandscrewfittings.

Strainer blocked ÎClean strainer.

Jerkycontrolresponse

Increased friction, e.g. due to foreign particles between seat and plug

ÎRemove foreign particles. ÎWhen parts are damaged, contact SAMSON’s After-sales Service.

Loud noises Highflowvelocity,cavitation ÎCheckthesizing. Î Install larger regulator, if necessary. Î Installflowdividerwithgasesandsteam.

Leakage at the actuator

Defectiveoperatingdiaphragm/bel-lows ÎReplacedamageddiaphragm/bellows.

Leakage at the bellows seal Defective bellows seal ÎWhen parts are damaged, contact SAMSON’s

After-sales Service.

Red mark appears at the diaphragm rupture indicator (actuator with two diaphragms).

Defective operating diaphragm ÎReplace damaged operating diaphragm.

EB 2512 EN 8-3

Malfunctions

Contact SAMSON’s After-sales Service for malfunctions not listed in the table.

Themalfunctionslistedinsection 8.1arecaused by mechanical faults and incorrect regulatorsizing.Inthesimplestcase,thefunctioning can be restored following the recommended action. Special tools may be required to remedy the fault.Exceptionaloperatingandinstallationcondi-tions may lead to changed situations that may affect the control response and lead to malfunctions. For troubleshooting, the condi-tions, such as installation, process medium, temperature and pressure conditions, must be taken into account.

SAMSON's After-sales Service department can support you in drawing up an inspection and test plan for your plant.

Note

Tip

8.2 Emergency actionThe plant operator is responsible for emer-gency action to be taken in the plant.We recommend removing the regulator from the pipeline before repairing it.In the event of a regulator malfunction:1. Close the shut-off valves upstream and

downstream of the regulator to stop the processmediumfromflowingthroughthe regulator.

2. Perform troubleshooting (see sec-tion 8.1).

3. Rectify those malfunctions that can be remedied based on the instructions pro-vided here. Contact our after-sales ser-vice in all other cases.

Putting the valve back into operation after a malfunctionSee the 'Start-up' section.

8-4 EB 2512 EN

EB 2512 EN 9-1

Servicing

9 ServicingThe regulator does not require any mainte-nance. Nevertheless, it is subject to natural wear, particularly at the seat, plug and oper-atingdiaphragm/bellows.Dependingontheoperating conditions, check the regulator at regular intervals to avoid possible malfunc-tions. Operators are responsible for drawing up an inspection and test plan. Details on faults and how to remedy them can be found in the 'Malfunctions' section.The work described in this section is only to beperformedbypersonnelqualifiedfortheassignment accordingly.We recommend removing the regulator from the pipeline before performing any mainte-nance or service work.




WARNING!

Risk of personal injury due to residual pro-cess 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.


Risk of regulator damage due to exces-sively high or low tightening torques.Observe the specified torques on tightening regulator components. Excessively tightened torques lead to parts wearing out quicker. Parts that are too loose may cause leakage.

Î Observe the specified tightening torques (see Annex).

Risk of regulator damage due to the use of unsuitable tools.

Î Only use tools approved by SAMSON (see Annex).

Risk of regulator damage due to the use of unsuitable lubricants.

Î Only use lubricants approved by SAMSON (see Annex).

WARNING! WARNING!

NOTICE!

NOTICE!

NOTICE!

9-2 EB 2512 EN

Servicing

The regulator was checked by SAMSON before it left the factory.

−Certain test results (seat leakage and leak test) certified by SAMSON lose their validi-ty when the regulator is opened. − The product warranty becomes void if service or repair work not described in these instructions is performed without prior agreement by SAMSON's After-sales Service. −Only use original spare parts by SAMSON, which comply with the original specifications.

SAMSON's After-sales Service can support you in drawing up an inspection and test plan for your plant.

Note

Tip

LegendforFig. 9-1

1 Valve body2 Seat3 Plug4 Balancingbellows5 Plug stem5.1 Bellows6 Set point adjuster7 Set point springs7.1 Spring plate8 Crossbeam

8.1 Pillar(viewdrawnturnedby90°)

8.2 Nuts for pillars8.3 Tapped holes9 Fastening nuts10 Diaphragmactuator/bellowsactuator11 Actuator stem12 Operating diaphragm12.1 Operating bellows13 Diaphragm plate14 Diaphragm plate nut15 Nuts and bolts

16ControllineconnectionG ¼(with screw joint with restriction when used with steam)

17Control line (to be provided on site)(available as control line kit for direct pres-sure tapping at the body u T 2595)

18 Compensation chamber19 Filler plug20 Travel stop cap with cotter pin


EB 2512 EN 9-3

Servicing

2

3

4

5

6

7

5.1

10

11

12 16

1819

17

1

89

15

20

13 14

8.2

8.1

8.2

p1 p2

7.1

Type 2412 Valve

Type 2413DiaphragmActuator

12.1

16

8.2

10

Bellowsactuator forDN 15to50

8.3

10

16

Bellowsactuator forDN 65to100

Type 2413BellowsActuatorfor2to6,5to10,10to22and20to28 bar

Fig. 9-1: Functional diagram for regulators, DN 32 to 100 with balancing bellows

9-4 EB 2512 EN

Servicing

9.1 Preparing the valve for servicework

1. Lay out the necessary material and tools to have them ready for the service work.

2. Put the regulator out of operation (see the 'Decommissioning' section).

We recommend removing the regulator from the pipeline before performing any service work (see the 'Removing the valve from the pipeline' section).

The following service work can be per-formed after preparation is completed:

− Replacing the actuator (see sec-tion 9.3.1)

− Replacing the set point springs (see sec-tion 9.3.2)

− Replacing the seat and plug (see sec-tion 9.3.3)

− Replacing the operating diaphragm (see section 9.3.4)

9.2 Installing the regulator afterservicework

Î Put the regulator back into operation (see the 'Start-up' section). Make sure re-quirements and conditions for start-up are met.

Tip

9.3 Servicework Î Beforeperforminganyservicework,preparations must be made to the regu-lator(seesection 9.1).

Î After all service work is completed, check the regulator before start-up (see 'Testing the regulator' in the 'Installation' section).

EB 2512 EN 9-5

Servicing

Mounting the actuator1. DiaphragmactuatorDN 15to100

Insert the actuator stem (11) through the hole in the crossbeam (8) into the travel stop cap with cotter pin (20) and fasten the actuator with the nuts (9). Observe thetighteningtorquesspecifiedinthetheAnnex.

− BellowsactuatorDN 15to50Insert the actuator stem (11) into the trav-el stop cap with cotter pin (20).Align actuator on the pillars (8.1) and fasten it with the nuts (8.2). Observe the tighteningtorquesspecifiedinthetheAnnex.

− BellowsactuatorDN 65to100Screw the pillars (8.1) into the threaded holes(8.3)oftheactuatorflangeasfaras they will go.Insert the actuator stem (11) into the trav-el stop cap with cotter pin (20).Fasten the pillars (8.1) with the nuts (8.2) ontothevalveflange.Observethetight-eningtorquesspecifiedinthetheAnnex.


3. Screw on the control line (17). Observe thetighteningtorquesspecifiedinthetheAnnex.

4. Put the regulator into operation (see the 'Operation' section).

9.3.1 Replacing the actuator Î RefertoFig. 9-1

Removing the actuator1. Put the regulator out of operation (see

the 'Decommissioning' section).2. Unscrew the control line (17).3. Completely relieve the tension from the

set point springs (7) by turning the set point adjuster (6) counterclockwise ().

Stored energy in the set point springs can cause components to move in an uncon-trolled manner resulting in injury to hands or fingers.

4. Unlock the cotter pin (20) on the travel stop cap.

5. DiaphragmactuatorDN 15to100Unscrew the nuts (9) from the actuator and remove the actuator.

− BellowsactuatorDN 15to50Unscrew the nuts (8.2) from the actuator and remove the actuator.

− BellowsactuatorDN 65to100Unscrew the nuts (8.2) on the pillars (8.1).Unscrew the pillars (8.1) out of the threaded holes (8.3) of the actuator flangeandremovetheactuator.

WARNING! WARNING!

9-6 EB 2512 EN

Servicing

9.3.2 Replacing the set point springs

Î RefertoFig. 9-1

Removing the set point springs1. Put the regulator out of operation (see

the 'Decommissioning' section).2. Completely relieve the tension from the



3. Unscrew the control line (17).4. Remove the device from the pipeline5. Unlock the cotter pin (20) on the travel

stop cap.6. Remove the actuator (10) from the valve

(seesection 9.3.1).7. Unscrew the nuts (8.2) on the crossbeam.

Remove the crossbeam (8).8. Remove the travel stop cap with cotter

pin (20) and spring plate (7.1).9. Lift off the set point springs (7).

WARNING! WARNING!

Mounting the set point springs1. Place the set point springs (7) on the set

point adjuster (6).2. Place on the spring plate (7.1) and the

travel stop cap with cotter pin (20).Place the crossbeam (8) on the pillars (8.1) and fasten with the nuts (8.2). Ob-servethetighteningtorquesspecifiedinthetheAnnex.

3. Mount the actuator (10) (see sec-tion 9.3.1).ObservethetighteningtorquesspecifiedinthetheAnnex.


5. Install the regulator into the pipeline.6. Screw on the control line (17). Observe

thetighteningtorquesspecifiedinthetheAnnex.


Change the nameplate and configuration ID after changing the set point range.

Note

EB 2512 EN 9-7

Servicing

9.3.3 Replacing the seat and plug

To replace seat and plug, contact SAMSON's After-sales Service.Further information is available in the the Annex.

9.3.4 Replacing the operating diaphragm

Do not exchange the operating diaphragm in an FDA-compliant regulator version.SAMSON's After-sales Service can support you to perform such service work.

There are no spare parts available for the bellows actuators. The entire actuator must be replaced if it is defective.

The associated order number is written on the actual operating diaphragm.

NOTICE!

Note

Tip

Î RefertoFig. 9-1

Removing the operating diaphragm1. Put the regulator out of operation (see

the 'Decommissioning' section).2. Completely relieve the tension from the



3. Unscrew the control line (17).4. Unscrew the nuts (9) and remove the ac-

tuator.5. Clamp the actuator stem (11) into a suit-

ablefixture.Markthesideoftheactua-tor to avoid reassembling it the wrong way.

6. Unscrew nuts and bolts (15) from the ac-tuator. Remove the actuator case with control line connection (16).

7. Unscrew the diaphragm plate nut (14) and remove the operating diaphragm (12) from the diaphragm plate (13).

WARNING! WARNING!

9-8 EB 2512 EN

Servicing

Mounting the operating diaphragm1. Place a new operating diaphragm (12)

onto the diaphragm plate (13) (ensuring thepressurizedsideisfacinginthecor-rect direction) and tighten the diaphragm plate nut (14). Observe the tightening torquesspecifiedinthetheAnnex.

2. Place on the actuator case with control line connection (16). Check the correct position of the control line connection nipple (marking).

3. Insert nuts and bolts (15) and tighten gradually in a crisscross pattern. Ob-servethetighteningtorquesspecifiedinthetheAnnex.

4. Insert the actuator into the travel stop cap with cotter pin (20) and tighten the fas-tening nuts (9). Observe the tightening torquesspecifiedinthetheAnnex.

5. Screw on the control line (17). Observe thetighteningtorquesspecifiedinthetheAnnex.


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 partsSeeAnnexfordetailsonspareparts.

Lubricant

Contact SAMSON's After-sales Service for more information on lubricants.

Tools

Contact SAMSON's After-sales Service for more information on tools.

EB 2512 EN 10-1

Decommissioning

10 DecommissioningThe work described in this section is only to beperformedbypersonnelqualifiedfortheassignment accordingly.

Risk of bursting due to incorrect opening of pressurized equipment or components.Regulators and pipelines are pressure equip-ment that may burst when handled incor-rectly. Flying projectile fragments or the re-lease of compressed medium can cause seri-ous injury or even death.Before working on the regulator:

Î Depressurize all plant sections affected and the regulator.

Î Disconnect the control line. Î Drain the process medium from all the plant sections affected as well as the valve.




DANGER!

WARNING!




Î Wear hearing protection when working near the regulator.





WARNING!

WARNING!

WARNING! WARNING!

10-2 EB 2512 EN

Decommissioning



WARNING! WARNING!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. Completely drain the pipelines and

valve.4. Depressurizetheplant.5. Shutoffordisconnectanyexternalcon-

trol line.6. If necessary, allow the pipeline and reg-

ulator components to cool down or heat up.

EB 2512 EN 11-1

Removal

11 RemovalThe work described in this section is only to beperformedbypersonnelqualifiedfortheassignment accordingly.






WARNING!

WARNING! WARNING!

Beforeremovingthevalve,makesurethefol-lowing conditions are met:

− The control valve is put out of operation (see the 'Decommissioning' section).

11.1 Removing the valve from the pipeline

1. Support the regulator to hold it in place when separated from the pipeline (see the 'Shipment and on-site transport' sec-tion).

2. Undoanyexternallymountedcontrolline.

3. Unbolttheflangejoint.4. Remove the regulator from the pipeline

(see the 'Shipment and on-site transport' section).

11.2 Removing the actuator from the valve

See 'Servicing' section.

11-2 EB 2512 EN

EB 2512 EN 12-1

Repairs

12 RepairsIf the regulator does not function properly accordingtohowitwasoriginallysizedordoes not function at all, it is defective and mustberepairedorexchanged.

Risk of regulator damage due to incorrect repair work.

Î Do not perform any repair work on your own.

Î Contact SAMSON's After-sales Service for repair work.

12.1 Returning devices to SAMSON

Defective devices can be returned to SAMSON for repair.Proceed as follows to return devices:1. Exceptionsapplyconcerningsome

special device models u www.samsongroup.com > Service & Support > After-sales Service.

NOTICE! NOTICE!

2. Send an e-mail u [email protected] to register the return shipment including the following information: – Type – Article no. – ConfigurationID – Original order – Completed Declaration on Contami-

nation, which can be downloaded from our website at u www.samsongroup.com > Service & Support > After-sales Service.

Aftercheckingyourregistration,wewillsend you a return merchandise authori-zation (RMA).

3. Attach the RMA (together with the Decla-ration on Decontamination) to the out-side of your shipment so that the docu-ments are clearly visible.

4. Send the shipment to the address given on the RMA.

Further information on returned devices and how they are handled can be found at u www.samsongroup.com > Service & Support > After-sales Service.

Note

https://www.samson.de/en/service-support/after-sales-service/






12-2 EB 2512 EN

EB 2512 EN 13-1

Disposal

13 Disposal Î Observe local, national and internation-al refuse regulations.

Î Do not dispose of components, lubricants andhazardoussubstancestogetherwithyour household waste.

13-2 EB 2512 EN

EB 2512 EN 14-1

Certificates

14 CertificatesThe declarations of conformity are included onthenextpages:

− Declaration of conformity in compliance with Pressure Equipment Directive 2014/68/EUonpage 14-2.

− Declaration of conformity in compliance withMachineryDirectiveforType 41-23Regulatoronpage 14-4.

− Declaration of incorporation in compli-ance with Machinery Directive 2006/42/ECfortheType 2412Valvewith other actuators other than the Type 2413Actuatoronpage 14-5.

14-2 EB 2512 EN

SAMSON AKTIENGESELLSCHAFT Weismüllerstraße 3 60314 Frankfurt am Main

Telefon: 069 4009-0 · Telefax: 069 4009-1507 E-Mail: [email protected]

Revision 03

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. 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

Richtlinie des Europäischen Parlaments und des Rates zur Harmonisierung der Rechtsvorschriften der Mitgliedstaaten über die Bereitstellung von Druckgeräten auf dem Markt.

2014/68/EU vom 15.05.2014

Directive of the European Parliament and of the Council on the harmonization of the laws of the Member States relating of the making available on the market of pressure equipment (see also Articles 41 and 48).

2014/68/EU of 15 May 2014

Angewandtes Konformitätsbewertungsverfahren für Fluide nach Art. 4(1)(c.i) erster Gedankenstrich. Modul siehe Tabelle

durch certified by

Bureau Veritas S. A. (0062)

Conformity assessment procedure applied for fluids according to Article 4(1)(c.i), first indent See table for module

Nenndruck Pressure rating

DNNPS

15½

20¾

251

321¼

401½

502

65-

803

1004

125-

1506

2008

25010

30012

40016

PN 16 ohne/without (1) A (2)(3) - - - - - - - - - PN 25 ohne/without (1) A (2)(3) H PN 40 ohne/without (1) H - PN 100 und PN 160 ohne/without (1) H - - - - Class 150 ohne/without (1) A (2)(3) H - Class 300 ohne/without (1) H Class 600 und Class 900 ohne/without (1) H - - - -

(1) Das auf dem Stellgerät aufgebrachte CE-Zeichen hat keine Gültigkeit im Sinne der Druckgeräterichtlinie. The CE marking affixed to the control valve is not valid in the sense oft the Pressure Equipment Directive.

(2) Das auf dem Stellgerät aufgebrachte CE-Zeichen gilt ohne Bezeichnung der benannten Stelle (Kenn-Nr. 0062). The CE marking affixed to the control valve is valid without specifying the notified body (ID number 0062).

(3) Die Identifikationsnummer 0062 von Bureau Veritas S.A. gilt nicht für Modul A. The identification number 0062 of Bureau Veritas S.A. is not valid for Modul A.

Geräte, denen laut Tabelle das Konformitätsbewertungsverfahren Modul H zugrunde liegt, beziehen sich auf die „Zulassungsbescheinigung eines Qualitätssicherungssystems“ ausgestellt durch die benannte Stelle. Devices whose conformity has been assessed based on Module H refer to the certificate of approval for the quality management system issued by the notified body. Dem Entwurf zu Grunde gelegt sind Verfahren aus:/The design is based on the methods of: DIN EN 12516-2, DIN EN 12516-3 bzw./or ASME B16.1, ASME B16.24, ASME B16.34, ASME B16.42 Das Qualitätssicherungssystem des Herstellers wird von folgender benannter Stelle überwacht: The manufacturer’s quality management system is monitored by the following notified body:

Bureau Veritas S.A. Nr./No. 0062, Newtime, 52 Boulevard du Parc, IIle de la Jatte, 92200 Neuilly sur Seine, France Hersteller:/Manufacturer: SAMSON AG, Weismüllerstraße 3, 60314 Frankfurt am Main, Germany

Frankfurt am Main, 08. Februar 2017/08 February 2017

Klaus Hörschken Dr. Michael Heß Zentralabteilungsleiter / Head of Central Department Zentralabteilungsleiter / Head of Central Department Entwicklung Ventile und Antriebe / R&D, Valves and Actuators Product Management & Technical Sales

EU-K

onfo

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1

EB 2512 EN 14-3

SAMSON AKTIENGESELLSCHAFT Weismüllerstraße 3 60314 Frankfurt am Main

Telefon: 069 4009-0 · Telefax: 069 4009-1507 E-Mail: [email protected]

Revision 03

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. 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.

Richtlinie des Europäischen Parlaments und des Rates zur Harmonisierung der Rechtsvorschriften der Mitgliedstaaten über die Bereitstellung von Druckgeräten auf dem Markt.

2014/68/EU vom 15.05.2014

Directive of the European Parliament and of the Council on the harmonization of the laws of the Member States relating of the making available on the market of pressure equipment.

2014/68/EU of 15 May 2014

Angewandtes Konformitätsbewertungsverfahren für Fluide nach Art. 4(1)(c.ii) und (c.i) zweiter Gedankenstrich.

Modul siehe Tabelle

durch certified by

Bureau Veritas S. A. (0062) Conformity assessment procedure applied for fluids according to Article 4(1)(c.ii) and (c.i), second

indent See table for

module

Nenndruck Pressure rating

DNNPS

15½

20¾

251

321¼

401½

502

65-

803

1004

125-

1506

2008

25010

30012

40016

PN 16 ohne/without (1) A (2)(3) H PN 25 ohne/without (1) A (2)(3) H PN 40 ohne/without (1) A (2)(3) H - PN 100 und PN 160 ohne/without (1) H - Class 150 ohne/without (1) A (2)(3) H - Class 300 ohne/without (1) A (2)(3) H Class 600 und Class 900 ohne/without (1) H -

(1) Das auf dem Stellgerät aufgebrachte CE-Zeichen hat keine Gültigkeit im Sinne der Druckgeräterichtlinie. The CE marking affixed to the control valve is not valid in the sense of the Pressure Equipment Directive.

(2) Das auf dem Stellgerät aufgebrachte CE-Zeichen gilt ohne Bezeichnung der benannten Stelle (Kenn-Nr. 0062). The CE marking affixed to the control valve is valid without specifying the notified body (ID number 0062).

(3) Die Identifikationsnummer 0062 von Bureau Veritas S.A. gilt nicht für Modul A. The identification number 0062 of Bureau Veritas S.A. is not valid for Modul A.

Geräte, denen laut Tabelle das Konformitätsbewertungsverfahren Modul H zugrunde liegt, beziehen sich auf die „Zulassungsbescheinigung eines Qualitätssicherungssystems“ ausgestellt durch die benannte Stelle. Devices whose conformity has been assessed based on Module H refer to the certificate of approval for the quality management system issued by the notified body. Dem Entwurf zu Grunde gelegt sind Verfahren aus:/The design is based on the procedures specified in the following standards: DIN EN 12516-2, DIN EN 12516-3 bzw./or ASME B16.1, ASME B16.24, ASME B16.34, ASME B16.42 Das Qualitätssicherungssystem des Herstellers wird von folgender benannter Stelle überwacht: The manufacturer’s quality management system is monitored by the following notified body:

Bureau Veritas S.A. Nr./No. 0062, Newtime, 52 Boulevard du Parc, IIle de la Jatte, 92200 Neuilly sur Seine, France Hersteller:/Manufacturer: SAMSON AG, Weismüllerstraße 3, 60314 Frankfurt am Main, Germany

Frankfurt am Main, 08. Februar 2017/08 February 2017

Klaus Hörschken Dr. Michael Heß Zentralabteilungsleiter/Head of Central Department Zentralabteilungsleiter/Head of Central Department Entwicklung Ventile und Antriebe/R&D, Valves and Actuators Product Management & Technical Sales

EU-K

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14-4 EB 2512 EN

2

EB 2512 EN 14-5

3

14-6 EB 2512 EN

EB 2512 EN 15-1

Annex

15 Annex

15.1 Tightening torquesTable 15-1: Tightening torque

Component Widthacrossflats Valve size/actuator area Tighteningtorquein Nm

Set point adjuster (6)SW 19 DN 15to50

–SW 24 DN 65to100

Nuts for pillars (8.2) SW 24 DN 15to100 60

Fastening nuts (9) SW 16 DN 15to100 25

Diaphragm plate nut (14) SW 12 40to640 cm² 40

Nuts and bolts (15) – 40to640 cm² 25

Control line connection (16) – 40to640 cm² 22

15.2 LubricantSAMSON's After-sales Service can support you concerning lubricants and sealants ap-proved by SAMSON.

15.3 ToolsSAMSON's After-sales Service can support you concerning lubricants and sealants ap-proved by SAMSON.

15.4 Accessories

Table 15-1: Assignment of compensation chamber (18) to regulator, with item no.

Type 2413Actuator Actuator area A

Item numberCompensation chamber

DN 15to50 DN 65to100

640 cm² 1190-8789 1190-8790

320 cm² 1190-8788 1190-8789

160,80,40 cm² 1190-8788

15-2 EB 2512 EN

Annex

15.5 Spare parts

Version(September2012onwards)1 Bellows2 Bellowsassembly6 Coupling nut

12 Balancingscrew16 Seat17 Plug

17.1 Pre-stage of plug17.2 Seal20 Body21 Guidecap25 Guide(DN 32to100)

25, 26 Guidebushing/pipe(DN 15to25)27 Flanged pipe28 Washer34 Flange40 Set point adjuster42 Retaining washer44 Pillar46 Seal51 Stud52 Hexnut60 Flow divider

70, 71 Spring73 Travel stop cap with cotter pin74 Spring plate75 Seal76 Axialneedlebearing

16

17

12

Standardversion(DN 15to25)

77 Lock washer79 Hexnut80 Crossbeam

101, 102 Diaphragm case103 Screw plug104 Diaphragm stem105 Diaphragm plate106 Diaphragm washer108 Operating diaphragm111 Hexbolt

112 - 114 Hexnut116 Washer

16

17.1

17.2

17

12

Versionwithsoft-seatedplug

16

60

17

12

Versionwithflowdivider

EB 2512 EN 15-3

Annex

79

16

12

42

17

25/26

21

28

51

52

40

46

34

27

2

108

106

114

105

79

44

71

75

74

77

76

6

80

113

116

102

101

112

111

70

20

103

1

104

73

15-4 EB 2512 EN

Annex

There are no spare parts available for the bellows actuators. The entire actuator must be replaced if it is defective.

Note 15.6 After-sales serviceContact SAMSON's After-sales Service for support concerning service or repair work or when malfunctions or defects arise.E-mail addressYou can reach our after-sales service at [email protected].

AddressesofSAMSON AGanditssubsid-iariesThe addresses of SAMSON, its subsidiaries, representatives and service facilities world-wide can be found on our website (u www.samson.de)orinallSAMSONproduct catalogs.

RequiredspecificationsPlease submit the following details:

− Devicetypeandnominalsize − ModelnumberandconfigurationID − Upstream and downstream pressure − Temperature and process medium − Min.andmax.flowrate − Is a strainer installed? − Installationdrawingshowingtheexact

location of the regulator and all the ad-ditionally installed components (shut-off valves, pressure gauge etc.)

mailto:aftersalesservice%40samson.de?subject=

http://www.samson.de/

2020

-06-23·English

SAMSON AKTIENGESELLSCHAFTWeismüllerstraße 3 · 60314 Frankfurt am Main, GermanyPhone: +49 69 4009-0 · Fax: +49 69 [email protected] · www.samson.de

EB 2512 EN

eb 2512 en - samson · eb 2512 en 1-1 safety instructions and measures 1 safety instructions and...

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