Samson 2405 Series Mounting And Operating Instructions

Page 1
Mounting and Operating Instructions
EB 2520 EN
Translation of original instructions
Edition June 2017
Type2405 Pressure Reducing Valve
Page 2
2 EB 2520 EN
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.
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 (aftersalesservice@samson.de).
The mounting and operating instructions for the devices are included in the scope of delivery. The latest documentation is available on our website (www.samson.de) > Product documentation. You can enter the document
number or type number in the [Find:] eld to look for a document.
Denition 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
Page 3
Contents
EB 2520 EN 3
1 Safety instructions and measures ...................................................................5
1.1 Notes on possible severe personal injury .........................................................7
1.2 Notes on possible personal injury ...................................................................7
1.3 Notes on possible property damage ................................................................8
2 Markings on the device .................................................................................9
3 Design and principle of operation ................................................................10
3.1 Versions ......................................................................................................11
3.2 Technical data .............................................................................................12
4 Measures for preparation ............................................................................16
4.1 Unpacking ..................................................................................................16
4.2 Transporting and lifting ................................................................................16
4.3 Storage .......................................................................................................16
4.4 Preparation for installation ............................................................................17
5 Mounting and start-up ................................................................................. 18
5.1 Installing the valve into the pipeline ...............................................................18
5.1.1 Installation conditions ...................................................................................18
5.1.2 Mounting position ........................................................................................18
5.1.3 Additional ttings .........................................................................................19
5.2 Quick check ................................................................................................20
5.3 Putting the regulator into operation ................................................................21
5.4 Adjusting the set point ..................................................................................21
6 Servicing.....................................................................................................22
6.1 Preparation for return shipment ..................................................................... 22
6.2 Ordering spare parts and operating supplies .................................................23
7 Malfunctions ...............................................................................................24
7.1 Troubleshooting ...........................................................................................24
8 Decommissioning and disassembly ..............................................................25
8.1 Decommissioning .........................................................................................25
8.2 Removing the valve from the pipeline .............................................................25
8.3 Disposal ......................................................................................................25
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4 EB 2520 EN
Contents
9 Annex.........................................................................................................26
9.1 After-sales service ........................................................................................26
9.2 Certicates ..................................................................................................26
Page 5
EB 2520 EN 5
Safety instructions and measures
1 Safety instructions and measures
Intended use
The Type2405 Pressure Reducing Valve is used to control the pressure of ammable gases
used as a source of energy, e.g. in boilers, driers, vaporizers, heat exchangers or industrial ovens. Alternatively, it can control the compressed air supply in process engineering applica­tions.
The device is designed to operate under exactly dened conditions (e.g. operating pressure,
process medium, temperature). Therefore, operators must ensure that the device is only used
in applications that meet the specications used for sizing the device at the ordering stage. In case operators intend to use the device in other applications or conditions than specied,
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 elds of application as well as
possible uses.
Reasonably foreseeable misuse
The device is not suitable for use outside the limits dened during sizing and in the technical
data. Furthermore, the following activities do not comply with the intended use:
Use as safety valve
Use of non-original spare parts
Performing service and repair work not described in these instructions
Qualications of operating personnel
The device must be mounted, started up, serviced, and repaired by fully trained and quali­ed personnel only; the accepted industry codes and practices are to be observed. Accord­ing to these mounting and operating instructions, trained personnel refers to individuals who are able to judge the work they are assigned to and recognize possible hazards due to their specialized training, their knowledge and experience as well as their knowledge of the appli­cable standards.
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6 EB 2520 EN
Safety instructions and measures
Personal protective equipment
We recommend wearing the following protective equipment depending on the process medi­um:
Protective clothing, gloves, and eyewear in applications with hot, cold, and/or corrosive media
Î Check with the plant operator for details on further protective equipment.
Revisions and other modications
Revisions, conversions or other modications to the product are not authorized by SAMSON.
They are performed at the user's own risk and may lead to safety hazards, for example. Fur­thermore, the product may no longer meet the requirements for its intended use.
Warning against residual hazards
To avoid personal injury or property damage, operators and operating personnel must pre­vent hazards that could be caused in the device by the process medium and operating pres­sure by taking appropriate precautions. They must observe all hazard statements, warning and caution notes in these mounting and operating instructions, especially for installation, start-up, and service work.
Responsibilities of the operator
The operator is responsible for proper operation and compliance with the safety regulations. Operators are obliged to provide these mounting and operating instructions as well as the referenced documents to the operating personnel and to instruct them in proper operation. Furthermore, the operator must ensure that operating personnel or third persons are not ex­posed to any danger.
Responsibilities of operating personnel
Operating personnel must read and understand these mounting and operating instructions as well as the referenced documents and observe the hazard statements, warning and caution notes specied in them. Furthermore, the operating personnel must be familiar with the ap­plicable health, safety and accident prevention regulations and comply with them.
Referenced standards and regulations
The devices comply with the requirements of the European Pressure Equipment Directive 2014/68/EU. Devices with a CE marking have an EU declaration of conformity, which in­cludes information about the applied conformity assessment procedure. This declaration of
conformity is included in the Appendix of these instructions (see section9.2).
Page 7
EB 2520 EN 7
Safety instructions and measures
Non-electric valve versions whose bodies are not lined with an insulating material coating do not have their own potential ignition source according to the risk assessment stipulated in
EN13463-1:2009, section5.2, even in the rare incident of an operating fault. Therefore,
such valve versions do not fall within the scope of Directive 2014/34/EU.
Î For connection to the equipotential bonding system, observe the requirements specied in
section 6.4 of EN60079-14 (VDE0165 Part 1).
1.1 Notes on possible severe personal injury
DANGER
!
Risk of bursting in pressure equipment.
Control valves and pipelines are pressure equipment. Improper opening can lead to valve components bursting.
Î Before starting any work on the control valve, depressurize all plant sections con-
cerned as well as the valve.
Î To prevent uncontrolled excess pressure, make sure that suitable overpressure pro-
tection is installed on site in the plant section.
Î Drain the process medium from all the plant sections concerned as well as the
valve.
Î Wear personal protective equipment.
1.2 Notes on possible personal injury
WARNING
!
Risk of personal injury due to residual process medium in the valve.
While working on the valve, 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 concerned and the
valve.
Î Wear protective clothing, safety gloves, and eyewear.
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Safety instructions and measures
WARNING
!
Risk of burn injuries due to hot or cold components and pipelines.
Depending on the process medium, valve 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.
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 indi­cated on the SAMSON delivery note.
Î Information on safe use of the part affected, see uhttp://www.samson.de/reach-
en.html.
1.3 Notes on possible property damage
NOTICE
!
Risk of valve 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. Î Observe the maximum permissible pressure for valve and plant.
Risk of valve damage due to unsuitable medium properties.
The valve is designed for a process medium with dened properties.
Î Only use the process medium specied for sizing the valve.
Page 9
EB 2520 EN 9
Safety instructions and measures
NOTICE
!
Risk of leakage and valve damage due to excessively high or low tightening torques.
Observe the specied torques on tightening valve components.
Excessively tightened torques lead to parts wearing out quicker. Parts that are too loose may cause leakage.
Î Observe the specied tightening torques.
Risk of regulator damage due to incorrectly attached lifting equipment.
Î Do not attach lifting equipment to mounting parts (e.g. adjusting screw or control
line).
Conversion from chromate coating to iridescent passivation We at SAMSON are converting the surface treatment of passivated steel parts in our produc­tion. As a result, you may receive a device assembled from parts that have been subjected to different surface treatment methods. This means that the surfaces of some parts show differ­ent reections. Parts can have an iridescent yellow or silver color. This has no effect on corro­sion protection. For further information go to uwww.samson.de/chrome-en.html.
Note
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10 EB 2520 EN
Markings on the device
2 Markings on the device
SAMSON
4
6
231
7
89 11
5
10
Made in Germany
2009
xxxx
1 Type designation (2405) 2 Max. perm. operating pressure at the
actuator p
max
3 Conguration ID 4 Order number or date 5 K
VS
coefcient
7 Set point range/spring force
8 Nominal size 9 Nominal pressure 10 Permissible differential pressure (across
the valve) 11 Perm. temperature 12 Body material
The CE marking only exists for versions in nominal sizes DN32 to 50.
Fig.1: Nameplate
Note
Page 11
EB 2520 EN 11
Design and principle of operation
3 Design and principle of oper-
ation
The medium ows through the valve in the di­rection indicated by the arrow. The position of the plug (3) determines the cross-sectional
area of ow between the plug and seat (2).
In the pressureless state (control line not con­nected and no pressure applied) the valve is opened by the force of the set point springs (7).
The downstream pressure p
2
to be controlled is tapped downstream of the regulator and transmitted over an external control line to the control line connection (9) on the actua­tor housing (6) where it is converted into a
positioning force by the diaphragm plate with operating diaphragm (5). This force is used to move the plug stem (4) and the valve plug depending on the force of the set point springs. The spring force can be adjusted at the set point adjuster (8).
When the force resulting from the down­stream pressure p
2
rises above the spring force adjusted at the set point springs, the valve closes proportionally to the change in pressure.
In the version with pressure balancing, the forces produced by the upstream and down­stream pressures acting on the plug are elim­inated by the balancing diaphragm (10). The plug is fully balanced.
p
1
p
2
8
7
6
5
11
4 9
1
3
2
Fig.2: Type2405 Pressure Reducing Valve without pressure balancing · KVS 1.6 to 4 · Flow-to-open
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12 EB 2520 EN
Markings on the device
p
1
p
2
p
1
p
2
10
1 Valve body 2 Seat 3 Plug 4 Plug stem 5 Diaphragm plate with operating
diaphragm
6 Actuator housing
7 Set point spring 8 Set point adjuster (screw SW27)
9 Control line connection, G¼ tting 10 Balancing diaphragm 11 Leakage line connection (special version),
G¼ tting
Fig.3: Type2405 Pressure Reducing Valve
without pressure balancing · K
VS
0.016 to 1 · Flow-to-close
Fig.4: Type2405 Pressure Reducing Valve with
pressure balancing · KVS 6.3 to 32
3.1 Versions
Type2405 Pressure Reducing Valve to con­trol gases
Standard
Temperature range from –20 to +60°C
Set points from 5mbar to 10bar
Nominal size DN15 to 50
PN16 to 40
Flanges
Options
With pressure balancing (see Fig.4)
Pressure tapping directly at the valve in- stead of over an external control line
with 0.8 to 2.5bar, 2 to 5bar, and 4.5 to 10bar
Temperature range from 0 to 150°C for unbalanced versions with FKM dia­phragm and FKM soft seal
Page 13
EB 2520 EN 13
Markings on the device
3.2 Technical data
Table1: Technical data
Nominal size DN15 DN20 DN25 DN32, 40, 50
Nominal pressure (valve)
PN16 · PN25 · PN40
K
VS
coefcients
Standard
4
6.3
8
32
Reduced K
VS
coefcients
0.016 · 0.04
0.1 · 0.25 · 0.4 1 · 1.6 · 2.5
0.016 · 0.04
0.1 · 0.25 · 0.4 1 · 1.6 · 2.5 · 4
0.016 · 0.04
0.1 · 0.25 · 0.4 1 · 1.6 · 2.5 · 4
6.3
1.6 · 2.5 · 4
6.3 · 8 · 16
20
Max. permissible differential pressure 10bar · 12bar
1)
Max. permissible temperature range (medium temperature)
–20 to +60°C (0 to +150°C)
2)
Leakage class according to IEC60534-4 Soft-seated, minimum Class IV
Set point ranges
5 to 15mbar · 10 to 30mbar · 25 to 60mbar · 50 to 200mbar · 0.1 to
0.6bar · 0.2 to 1bar · 0.8 to 2.5bar · 2 to 5bar · 4.5 to 10bar
Max. perm. pressure at operating diaphragm
1200cm² 0.5bar
640cm² 1bar
320cm² 2bar · 10bar
3)
160cm² 3bar · 16bar
3)
80cm² 5bar · 16bar
3)
40cm² · 2 to 5bar 10bar · 16bar
3)
40cm² · 4.5 to 10bar 15bar · 16bar
3)
Pressure balancing
K
VS
=0.016 to 4 Without balancing diaphragm
K
VS
=6.3 to 32 With balancing diaphragm
Pressure tapping External
4)
Control line connection G ¼
1)
Version with set points from 0.1 to 10bar
2)
For unbalanced versions with FKM diaphragm and FKM soft seal
3)
Version with force limiter
4)
Special version with pressure tapping directly at the valve (see section3.1)
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14 EB 2520 EN
Markings on the device
Table2: Dimensions in mm
Nominal size DN15 DN20 DN25 DN32 DN40 DN50
Length L 130 150 160 180 200 230
Height H2
Forged steel 53 70 92 98
Other materials 44 72
Set point range
5 to 15mbar
Height H
Without balancing 325 370
With balancing 352 377
Actuator ØD = 490mm, A = 1200cm²
10 to 30mbar
Height H
Without balancing 318 366
With balancing 345 370
Actuator
ØD = 380mm,
A = 640cm²
ØD = 490mm,
A = 1200cm²
25 to 60mbar
Height H
Without balancing 318 366
With balancing 345 370
Actuator ØD=380mm, A=640cm²
50 to 200mbar
Height H
Without balancing 318 366
With balancing 345 370
Actuator ØD = 285mm, A = 320cm²
0.1 to 0.6bar
Height H
Without balancing 318 366
With balancing 345 370
Actuator ØD = 285mm, A = 320cm²
0.2 to 1bar
Height H
Without balancing 318 366
With balancing 345 370
Actuator ØD = 225mm, A = 160cm²
0.8 to 2.5bar
Height H
Without balancing 330 365
With balancing 356 369
Actuator ØD = 170mm, A = 80cm²
2 to 5bar
Height H
Without balancing 333 368mm
With balancing 359 373mm
Actuator ØD = 170mm, A = 40cm²
4.5 to 10bar
Height H
Without balancing 437 485
With balancing 463 489
Actuator ØD = 170mm, A = 40cm²
Page 15
EB 2520 EN 15
Markings on the device
Dimensional drawings
DN15 to 25 DN32 to 50
H
ØD
H2
H
ØD
L
L
H2
Control line connection G¼, for A = 40, 80,
160, and 320cm²
Control line connection G ¼, for A = 640 and
1200cm²
The control line connection is turned by 90° in the drawing. The connection is normally located
opposite the side with the arrow indicating the direction of ow.
G¼ tting
Control line connection at the side of the actuator
housing
Control line connection on the bottom of the
actuator housing
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16 EB 2520 EN
Markings on the device
Table3: Weights in kg
Nominal size DN15 DN20 DN25 DN32 DN40 DN50
Set point range
5 to 15mbar 28 40
10 to 30mbar 18 40
25 to 60mbar 14 30
50 to 200mbar 14 26
0.1 to 0.6bar 14 26
0.2 to 1bar 10 22
0.8 to 2.5bar 8 20
2 to 5bar 8 20
4.5 to 10bar 9 21
1)
Body made of cast steel 1.0619: +10%
Page 17
EB 2520 EN 17
Measures for preparation
4 Measures for preparation
After receiving the shipment, proceed as fol­lows:
1. Check the scope of delivery. Compare the shipment received against the deliv­ery note.
2. Check the shipment for transportation damage. Report any damage to SAMSON and the forwarding agent (refer to delivery note).
4.1 Unpacking
Do not remove the packaging until immedi­ately before installing the valve into the pipe­line.
Proceed as follows to lift and install the de­vice:
1. Remove the packaging from the device.
2. Dispose of the packaging in accordance with the valid regulations.
4.2 Transporting and lifting
Due to the low service weight, lifting equip­ment is not required to lift and transport the device (e.g. to install it into the pipeline).
Risk of valve damage due to incorrectly at­tached lifting equipment. Do not attach lifting equipment to mounting parts (e.g. adjusting screw or control line).
Transport instructions
Protect the device against external inu- ences (e.g. impact).
Do not damage the corrosion protection (paint, surface coatings). Repair any damage immediately.
Protect the device against moisture and dirt.
Observe the permissible ambient tem-
peratures (see section3.2).
4.3 Storage
Risk of regulator damage due to improper
storage.
− Observe storage instructions.
− Avoid long storage times.
Contact SAMSON in case of different stor­age conditions or long storage periods.
We recommend regularly checking the de­vice and the prevailing storage conditions during long storage periods.
Storage instructions
Protect the device against external inu- ences (e.g. impact).
Do not damage the corrosion protection (paint, surface coatings). Repair any damage immediately.
Protect the device against moisture and dirt. Store it at a relative humidity of less
NOTICE
!
NOTICE
!
Note
Page 18
18 EB 2520 EN
Measures for preparation
than 75%. In damp spaces, prevent con­densation. If necessary, use a drying agent or heating.
Make sure that the ambient air is free of acids or other corrosive media.
Observe the permissible ambient tem-
peratures (see section3.2).
Do not place any objects on the device.
4.4 Preparation for installation
Î Flush the pipelines.
The plant operator is responsible for clean­ing the pipelines in the plant.
Î Ensure that there is no liquid, e.g. con-
densed water, inside the regulator. If nec­essary, blow out the connecting parts with clean compressed air.
Î Check the valve to make sure it is clean. Î Check the valve for damage. Î Check to make sure that the type desig-
nation, valve size, material, pressure rat­ing, and temperature range of the valve match the plant conditions (size and pressure rating of the pipeline, medium temperature etc.).
Note
Page 19
EB 2520 EN 19
Mounting and start-up
5 Mounting and start-up
5.1 Installing the valve into the pipeline
5.1.1 Installation conditions
Choose a place of installation that allows you to freely access the regulator even after the entire plant has been complet­ed.
The type and dimensions of the pipeline and tank connections must suit the regu­lator.
Make sure the direction of ow matches the direction indicated by the arrow on the body.
Install the regulator free of stress and with the least amount of vibrations as possible. If necessary, support the pipe-
line near to the connecting anges. Do
not attach supports directly to the valve or actuator.
Protect the regulator from icing up when controlling media that can freeze. Re­move the regulator from the pipeline when the plant is shut down if the regula­tor is not installed areas free from frost.
Observe the permissible ambient tem-
peratures (see section3.2).
5.1.2 Mounting position
Standard
Preferably install the regulator in a horizon­tal pipeline. The actuator housing with set point adjuster must face upwards.
Fig.5: Installation in horizon-
tal pipelines
Î Install the control line to the tapping
point with an approx. 10% slope to al­low any condensing liquid to ow back
into the tank or pipe.
Options
Alternatively, the valve can be installed in a vertical pipeline. The actuator housing with set point adjuster must face sideways.
Fig.6: Installation in vertical
pipelines
Control deviations due to alternative installa­tion. System deviations may arise when the regu­lator is installed in vertical pipelines.
NOTICE
!
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20 EB 2520 EN
Mounting and start-up
5.1.3 Additional ttings
Strainer
We recommend installing a strainer (e.g. SAMSON Type2N) upstream of the regula­tor. It prevents solid particles in the process medium from damaging the valve.
Î Install the strainer upstream of the tem-
perature regulator. The arrow on the
valve indicates the direction of ow.
Î For installation in vertical pipeline: install
the strainer with the lter element facing
downwards.
Î Install the lter with sufcient space avail-
able to remove the lter.
Î Check the strainer at regular intervals
and clean it, if necessary.
Shut-off valve
Install a hand-operated shut-off valve both upstream of the strainer and downstream of the regulator. This allows the plant to be shut down for cleaning and maintenance, and when the plant is not used for longer periods of time.
Pressure gauges
Install a pressure gauge both upstream and downstream of the regulator to monitor the pressures prevailing in the plant.
min.
6 x DN
min. 12 x DN
DN
2
2
1
p
1
1
211
p
1
p
2
3
3
24
4
p
2
min.
5 x DN
~10% slope to
pressure tap­ping point
~10% slope to pressure
tapping point
1 Shut-off valve 2 Pressure gauge 3 Strainer 4 Control line
Fig.7: Sample application
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EB 2520 EN 21
Mounting and start-up
Control line
G¼ tting (9) on the actuator housing.
Route control line on site preferably using a
8x1mm (stainless) steel pipe (with min. 6mm inside diameter).
Always connect the control line connection
for pressure tapping (see Fig.7) directly to
the tank or vessel as the medium is in the ex­panded state and no turbulence occurs at this point.
If the pressure is to be tapped at a straight pipeline section, the largest possible distance to the regulator must be kept (at least 6 x DN). Connect the control line at the side or on top of the horizontally running main pipeline. If possible, place the point of pres­sure tapping in a pipe expansion.
Install any pipe ttings (e.g. restrictions,
bends, manifolds or branches), that may
cause turbulence in the ow, sufciently far
away from the control line connection (at least 6 x DN).
Regulators in special versions (set point
range 0.8 to 2.5bar, 2 to 5bar and 4.5 to 10bar) are supplied with the control line al-
ready connected to the valve body (see
Fig.8).
Fig.8: Control line
Regulator damage due to condensed water.
In applications in which the gas can liquefy, condensate may form in the control line, causing damage to the regulator. To allow condensate to run back into the tank, install
the control line with an approximate 10%
slope to the pressure tapping point at the
tank or pipeline (see Fig.7).
Leakage line connection
The regulator in the special version is deliv­ered with a leakage line connection. In this version, the opening to the set point adjust­ment is additionally sealed by a cap.
Connect the leakage line to the G¼ female thread tting on top of the actuator housing.
Fig.9: Leakage line connection G¼
In the event of a defective diaphragm (dia­phragm rupture) in the actuator, any process medium that escapes is fed through a leak­age line to a safe location.
NOTICE
!
Page 22
22 EB 2520 EN
Mounting and start-up
5.2 Quick check
Pressure test
A pressure test of the plant with the regulator already installed is only permissible up to the
nominal pressure of the valve (seeTable1).
The pressure at the operating diaphragm must not exceed the maximum permissible pressure. If this cannot be guaranteed, pro­ceed as follows: unscrew the control line at the actuator and seal the open control line. In case pressure surges are expected to oc­cur during start-up or during operation, in­stall a regulator with integrated force limiter
(special version, see Table1).
All plant components must be designed for the test pressure.
5.3 Putting the regulator into operation
1. Make sure the control line is correctly
connected and free of dirt. The cross-sec-
tional area of ow must be open.
2. Slowly open the shut-off valves on the
upstream pressure side.
3. Open all the valves on the consumer side
(downstream of the regulator). Avoid pressure surges.
5.4 Adjusting the set point
The regulator in the delivered state does not
have a dened pressure set point. The set
point spring is released of tension. The set point must be adjusted on starting up the plant.
Adjusting screw
(8), SW27
Fig.10: Set point adjustment (view from
above)
Adjust the required set point (seeFig.10) by
tensioning the set point springs (7) at the set point adjuster (8) using a suitable socket
wrench (width across ats 27).
1. Remove the cap (12).
2. Use a socket wrench (SW27) to turn the screw (8). Turn clockwise() to increase the pres- sure set point (the downstream pressure increases). Turn counterclockwise() to reduce the pressure set point (the downstream pres­sure drops).
Incorrect control due to a set point adjuster being turned too far. If the set point adjuster is turned too far, the regulator becomes blocked and closed-loop control is no longer possible. Only screw the set point adjuster up to the point where the spring tension can still be felt.
3. Remount the cap (12).
NOTICE
!
Page 23
EB 2520 EN 23
Mounting and start-up
The pressure gauge (Fig.7) installed on the
downstream side on site allows the adjusted set point to be monitored.
Page 24
24 EB 2520 EN
Servicing
6 Servicing
The regulators do not require any mainte­nance. Nevertheless, they are subject to nat­ural wear, particularly at the seat, plug, and operating diaphragm.
Risk of bursting in pressure equipment.
Control valves and pipelines are pressure equipment. Improper opening can lead to valve components bursting.
− Before starting any work on the control valve, depressurize all plant sections con­cerned as well as the valve.
− Drain the process medium from all the plant sections concerned as well as the valve.
− Wear personal protective equipment.
Risk of personal injury due to residual pro­cess medium in the valve. While working on the valve, residual process medium can escape and, depending on its properties, may lead to personal injury, e.g. (chemical) burns.
− If possible, drain the process medium from all the plant sections concerned and the valve.
− Wear protective clothing, safety gloves, and eyewear.
Risk of burn injuries due to hot or cold com­ponents and pipelines.
Depending on the process medium, valve components, and pipelines may get very hot or cold and cause burn injuries.
− Allow components and pipelines to cool down or heat up.
− Wear protective clothing and safety gloves.
The device was checked by SAMSON before it left the factory.
− Certain test results (seat leakage and leak
test) certied by SAMSON lose their
validity when the valve body or actuator housing 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 department.
− Only use original spare parts by SAMSON, which comply with the original
specications.
6.1 Preparation for return ship­ment
Defective valves can be returned to SAMSON for repair.
Proceed as follows to return devices to SAMSON:
1. Put the control valve out of operation (see
section8).
2. Decontaminate the valve. Remove any
residual process medium.
DANGER
!
WARNING
!
WARNING
!
Note
Page 25
EB 2520 EN 25
Servicing
3. Fill in the Declaration on Contamination, which can be downloaded from our website at uwww.samson.de > Services > Check lists for after sales service > Declaration on Contamination.
4. Send the valve together with the lled-in form to your nearest SAMSON subsidi­ary. SAMSON subsidiaries are listed on our website at uwww.samson.de > Contact.
6.2 Ordering spare parts and
operating supplies
Contact your nearest SAMSON subsidiary or the SAMSON After-sales Service depart­ment for information on spare parts, lubri­cants, and tools.
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26 EB 2520 EN
Malfunctions
7 Malfunctions
Depending on the operating conditions, check the regulator at certain intervals to prevent possible failure before it can occur. Operators are responsible for drawing up an inspection plan.
SAMSON's After-sales Service department can support you to draw up an inspection plan for your plant.
Tip
7.1 Troubleshooting
Malfunction Possible reasons Recommended action
Pressure uctuations and
vibrations
Pressure tapping incorrectly rout­ed.
Check the pressure tapping of
the control line (see section5.1.3
on Control line). If necessary, relocate the point of tapping.
Insufcient throttling. Screw SAMSON Venturi nozzle
into the tting for the control line
connection (9). Order no.:
1991-7114 for A=1200 or 640cm²
1991-7113 for A=320 or 160cm²
Improper sizing of the regulator. Check the sizing data used for
the regulator. If necessary, change the K
VS
coefcient, seat
diameter or diaphragm area.
Contact SAMSON's After-sales Service department for malfunctions not listed in the table.
Note
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EB 2520 EN 27
Decommissioning and disassembly
8 Decommissioning and disas-
sembly
Risk of bursting in pressure equipment.
Control valves and pipelines are pressure equipment. Improper opening can lead to bursting of the valve.
− Before starting any work on the control valve, depressurize all plant sections con­cerned as well as the valve.
− Drain the process medium from all the plant sections concerned as well as the valve.
− Wear personal protective equipment.
Risk of personal injury due to residual pro­cess medium in the valve. While working on the valve, residual process medium can escape and, depending on its properties, may lead to personal injury, e.g. (chemical) burns. Wear protective clothing, safety gloves, and eyewear.
Risk of burn injuries due to hot or cold com­ponents and pipeline.
Valve components and the pipeline may be­come very hot or cold. Risk of burn injuries.
− Allow components and pipelines to cool down or heat up.
− Wear protective clothing and safety gloves.
8.1 Decommissioning
To decommission the control valve for service and repair work or disassembly, proceed as follows:
1. Close the shut-off valve on the upstream side.
2. Close the shut-off valve on the down­stream side.
3. Completely drain the pipelines and valve.
4. Depressurize the plant.
5. If necessary, allow the pipeline and reg­ulator components to cool down or heat up.
8.2 Removing the valve from
the pipeline
1. Put the regulator out of operation (see
section8.1).
2. Unbolt the ange joint.
3. Remove the valve from the pipeline.
8.3 Disposal
Î Observe local, national, and internation-
al refuse regulations.
Î Do not dispose of components, lubri-
cants, and hazardous substances togeth­er with your other household waste.
DANGER
!
WARNING
!
WARNING
!
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28 EB 2520 EN
Annex
9 Annex
9.1 After-sales service
Contact SAMSON's After-sales Service de­partment for support concerning service or repair work or when malfunctions or defects arise.
E-mail
You can reach the After-sales Service De­partment at aftersalesservice@samson.
Addresses of SAMSONAG and its subsid­iaries
The addresses of SAMSON AG, its subsid­iaries, representatives, and service facilities worldwide can be found on the SAMSON website or in all SAMSON product catalogs.
Required specications
Please submit the following details:
Order number and position number in the order
Type, model number, nominal size, and valve version
Upstream and downstream pressure
Temperature and process medium
Min. and max. ow rate in m³/h
Is a strainer installed?
Installation drawing showing the exact location of the regulator and all the ad­ditionally installed components (shut-off valves, pressure gauge, etc.)
9.2 Certicates
The declaration of conformity is provided on the next page.
Page 29
EB 2520 EN 29
SAMSON AKTIENGESELLSCHAFT Weismüllerstraße 3 60314 Frankfurt a m Main
Telefon: 069 4009-0 · Telefax: 069 400 9-1507 E-Mail: samson@sam son.de
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
DN
NPS
15½ 20¾ 251 32
1¼ 401½ 502 65- 803
1004 125- 1506 2008 250
10
300
12
400
16
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
-Konformitaetserklaeru ng_Blatt-04_Modul-A_Modul-H_DE-EN_Rev.03_2017-02-08.docx
Page 30
30 EB 2520 EN
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EB 2520 EN 31
Page 32
SAMSON AG · MESS- UND REGELTECHNIK Weismüllerstraße 3 · 60314 Frankfurt am Main, Germany Phone: +49 69 4009-0 · Fax: +49 69 4009-1507 samson@samson.de · www.samson.de
EB 2520 EN
2018-03-29 · English
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