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Samson 45-6, Mounting And Operating Instructions

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Samson 45-6 Mounting And Operating Instructions Download Page 1

Translation of original instructions

EB 3226 EN

Type 45-6 Differential Pressure Regulator

Self-operated Regulators

Edition March 2020

Summary of Contents for 45-6

Page 1: ...Translation of original instructions EB 3226 EN Type 45 6 Differential Pressure Regulator Self operated Regulators Edition March 2020...

Page 2: ...perating 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 For the safe a...

Page 3: ...emoving the packaging from the regulator 4 1 4 3 Transporting and lifting the regulator 4 1 4 4 Storing the regulator 4 2 5 Installation 5 1 5 1 Installation conditions 5 1 5 2 Preparation for install...

Page 4: ...diaphragm 9 8 9 3 3 Replacing the set point springs 9 10 9 4 Ordering spare parts and operating supplies 9 11 10 Decommissioning 10 1 11 Removal 11 1 11 1 Removing the regulator from the pipeline 11 1...

Page 5: ...by external forces or any other external factors Refer to the technical data and nameplate for limits and fields of application as well as possible uses Reasonably foreseeable misuse The regulators ar...

Page 6: ...may no longer meet the requirements for its intended use Warning against residual hazards To avoid personal injury or property damage plant operators and operating personnel must prevent hazards that...

Page 7: ...the European Pressure Equipment Directive 2014 68 EU Regulators with a CE marking have an EU declaration of conformity which includes information about the applied conformity assessment procedure Thi...

Page 8: ...an lead to regulator components bursting Observe the maximum permissible pressure for regulator and plant If necessary a suitable overpressure protection must be installed on site in the plant section...

Page 9: ...ring loss or deafness due to loud noise The noise emissions depend on the regulator version plant facilities and process medi um Wear hearing protection when working near the regulator Crush hazard ar...

Page 10: ...ted 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 Information on safe use of the part affected u w...

Page 11: ...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 Only use...

Page 12: ...e use of unsuitable lubri cants and or contaminated tools and components Keep the regulator and the tools used free from solvents and grease Make sure that only suitable lubricants are used SAMSON s A...

Page 13: ...Set point range in bar 9 Max perm differential pressure p in bar 10 Arrow indicating the direction of flow 1 2 3 4 5 6 10 7 8 9 Fig 2 1 Nameplate 2 2 Location of the nameplates Nameplate position on t...

Page 14: ...2 2 EB 3226 EN Markings on the device...

Page 15: ...differential pressure to an adjustable set point The valve opens when the differential pressure rises The differential pressure to be controlled is transferred to the operating diaphragm 6 1 where it...

Page 16: ...ing nut 1 2 Body stopper DN 32 to 50 1 3 Seal 2 Seat 3 Plug balanced 3 1 Plug nut 3 2 Guide nipple 3 3 Plug nipple DN 32 to 50 3 4 Plug stem 3 5 Seal 3 6 Balancing piston 4 Diaphragm plate nut 5 Diaph...

Page 17: ...EB 3226 EN 3 3 Design and principle of operation 3 4 11 1 3 1 3 3 2 12 1 7 11 6 2 6 1 8 12 2 4 1 1 2 1 3 3 5 3 6 12 12 1 6 2 Fig 3 2 Functional diagram of the regulator DN 15 to 50 spring housing...

Page 18: ...6 5 1 3 9 _ _ 2 4 1 3 6 5 1 Shut off valve 2 Strainer 3 Pressure gauge 4 Differential pressure regulator 5 Pressure gauge 6 Shut off valve 9 Pump Fig 3 3 Sample application Strainers We recommend ins...

Page 19: ...1 to 4 bar Valve size DN 15 to 50 Pressure rating PN 25 Note Note The regulator is closed when relieved of pressure The valve opens when the differen tial pressure rises Leakage class The metal seated...

Page 20: ...0 1 to 1 bar 3 0 2 to 1 bar 0 5 to 2 bar 1 to 4 bar 1 Additional version Valve with flanged body made of spheroidal graphite iron 2 Diaphragm and seals made of FKM 3 Version with rotary knob and scale...

Page 21: ...ble 3 4 Dimensions in mm and weights Including connecting parts Valve size DN 15 20 25 32 40 50 With welding ends Overall length L1 210 234 244 268 294 330 Weight approx kg 2 0 2 1 2 2 8 5 9 0 9 5 Wit...

Page 22: ...d welding ends With rotary knob and scale division Set point range 0 1 to 1 bar DN 15 to 32 D d R L SW L1 H1 H H2 Type 45 6 with flanged body valve H1 L3 D Connection nuts with threaded ends L2 A Conn...

Page 23: ...ection 4 2 Removing the packaging from the regulator The regulator is delivered as an assembled unit Do not open or remove the packaging until immediately before lifting to install the regulator into...

Page 24: ...egulator against moisture and dirt Store it at a relative humidity of less than 75 In damp spaces prevent condensation If necessary use a drying agent or heating Make sure that the ambient air is free...

Page 25: ...Install the regulator allowing sufficient space to remove the actuator and valve or to perform service work on them Install the regulator free of stress and with the least amount of vibrations as pos...

Page 26: ...terial and tools to have them ready during installation work Flush the pipeline before installing the regulator The plant operator is responsible for cleaning the pipelines in the plant Check any moun...

Page 27: ...length a Outlet length b Gas Ma 0 3 2 4 Liquid Free of cavitation w 3 m s 2 4 Cavitation producing noise w 3 m s 2 4 Installation in a bypass pipe Installation in a short circuit pipe _ _ 2 4 6 5 1 3...

Page 28: ...pipe or a short circuit pipe see installation example in Fig 5 2 NOTICE NOTICE NOTICE 1 Close the shut off valves upstream and downstream of the regulator while the regulator is being installed 2 Rem...

Page 29: ...ing near the regulator DANGER DANGER WARNING 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 c...

Page 30: ...balancing piston Note NOTICE 5 5 Insulation To insulate cold systems we recommend first filling the plant and carefully rinsing it The regulator must not yet be insulated at this stage 1 Start up the...

Page 31: ...ive clothing and safety gloves DANGER WARNING WARNING WARNING Risk of personal injury due to pressurized components and process medium escaping under pressure Do not loosen the control line while the...

Page 32: ...ge in pressure and resulting high velocities that can damage the valve 3 Check the regulator to ensure it functions properly 6 2 Starting up the plant 1 Open the shut off valve 1 slowly first on the u...

Page 33: ...njury due to pressurized components and process medium escaping under pressure Do not loosen the control line while the valve is pressurized Risk of hearing loss or deafness due to loud noise Noise em...

Page 34: ...sure by approx 0 033 bar 0 2 0 4 0 6 0 8 1 0 1 2 0 1 2 3 4 5 6 p Scale division Fig 7 3 Set point adjusted according to the value on the scale Do not adjust the set point to a value on the scale lower...

Page 35: ...ssure set point not reached Regulator installed against the flow Install the regulator so that the direction of flow matches the direction indicated by the arrow on the body Regulator or KVS CV coeffi...

Page 36: ...rol response Restriction in the screw joint of the ac tuator dirty or too small Clean screw joint or install larger screw joint Dirt in the control line Clean the control line Jerky control response I...

Page 37: ...into account SAMSON s After sales Service can support you in drawing up an inspection and test plan for your plant Tip 8 2 Emergency action Operators are responsible for emergency ac tion to be taken...

Page 38: ...8 4 EB 3226 EN...

Page 39: ...ny work on the regulator depressurize all plant sections affected as well as the regulator Drain the process medium from all the plant sections affected as well as the regulator Wear personal protecti...

Page 40: ...ead to parts wearing out quicker Parts that are too loose may cause leakage Observe the specified tightening torques see Tightening torques in Annex NOTICE NOTICE NOTICE NOTICE The regulator was check...

Page 41: ...embly DN 32 to 50 3 4 Plug stem 3 5 Seal 3 6 Balancing piston 4 Diaphragm plate nut 5 Diaphragm plate 6 Actuator housing 6 1 Operating diaphragm p1 p2 1 2 1 1 1 2 3 4 3 3 11 1 3 1 3 3 2 5 11 6 6 1 7 8...

Page 42: ...9 4 EB 3226 EN Servicing 3 4 11 1 3 1 3 3 2 12 1 7 11 6 2 6 1 8 12 2 4 1 1 2 1 3 3 5 3 6 Fig 9 2 Functional diagram of the regulator DN 15 to 50 spring housing with manual adjuster...

Page 43: ...reparation is completed Replacing the seat and plug see sec tion 9 3 1 Replacing the operating diaphragm see section 9 3 2 Replacing the set point springs see sec tion 9 3 3 Tip 9 2 Installing the reg...

Page 44: ...seal 3 5 11 Thoroughly clean the seat 2 plug 3 and balancing piston 3 6 Replace damaged parts with new ones 12 Check the control line 11 for any block ages 13 Unscrew the seat 2 using a seat wrench i...

Page 45: ...the plug 3 onto the plug stem and screw on the plug nut 3 1 Observe the specified tightening torques see Tighten ing torques in Annex 5 Renew the seal 1 3 and insert it into the valve body 6 Screw in...

Page 46: ...int spring 1 Put the regulator out of operation see the Decommissioning section 2 Completely relieve the tension from the set point spring 8 by turning the set point adjuster 10 counterclockwise 3 Rem...

Page 47: ...y 1 and tighten the body screws 7 evenly Observe the specified tightening torques see Tightening torques in Annex 6 Use the SAMSON disassembly tool to screw the valve body 1 together with spring plate...

Page 48: ...ing 1 Put the regulator out of operation see the Decommissioning section 2 Completely relieve the tension from the set point spring 8 by turning the set point adjuster 10 counterclockwise 3 Remove the...

Page 49: ...our nearest SAMSON subsidiary or SAMSON s After sales Service for infor mation on spare parts lubricants and tools Spare parts See Annex for details on spare parts Lubricants See Annex for details on...

Page 50: ...9 12 EB 3226 EN Servicing...

Page 51: ...ents and the pipeline may become very hot or cold Risk of burn inju ries Allow components and pipelines to cool down or heat up Wear protective clothing and safety gloves DANGER WARNING WARNING Risk o...

Page 52: ...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 Depre...

Page 53: ...egulator 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 Wear protective clothing safety gloves and ey...

Page 54: ...11 2 EB 3226 EN...

Page 55: ...r sales Service 5 Send an e mail u retouren samsongroup com to register the return shipment including the following information NOTICE NOTICE Type Material number Item numbers of accessories Original...

Page 56: ...12 2 EB 3226 EN...

Page 57: ...EB 3226 EN 13 1 Disposal 13 Disposal Observe local national and internation al refuse regulations Do not dispose of components lubricants and hazardous substances together with your household waste...

Page 58: ...13 2 EB 3226 EN...

Page 59: ...6 EN 14 1 Certificates 14 Certificates The EU declarations of conformity are in cluded on the next pages EU declaration of conformity in compli ance with Pressure Equipment Directive 2014 68 EU on pag...

Page 60: ...e 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 Stellger t aufgebrachte CE Zeichen hat keine G ltigkeit im Sinne der Druckger terichtlinie The CE...

Page 61: ...N 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 Stellger t aufgebrachte CE Zeichen hat keine G ltigkeit...

Page 62: ...14 4 EB 3226 EN...

Page 63: ...o 50 110 Plug nut 3 1 SW 8 DN 15 to 32 4 SW 13 DN 40 to 50 8 Guide nipple 3 2 SW 19 DN 15 to 25 70 Plug nipple 3 3 SW 39 DN 32 to 50 110 Diaphragm plate nut 4 SW 17 DN 15 to 32 40 SW 19 DN 40 to 50 80...

Page 64: ...Set point springs 83 Diaphragm stem 90 Diaphragm plate 95 Spring plate 103 105 Washer 112 Actuator housing 116 Control line 124 125 Operating diaphragm 129 131 Housing screws 134 135 Seal 150 Axial ne...

Page 65: ...EB 3226 EN 15 3 Annex 205 212 226 206 224 129 131 6 2 31 34 30 26 186 187 134 135 221 215 207 216 208 210 7 116 155 Fig 15 1 Regulator DN 15 to 50 spring housing...

Page 66: ...B 3226 EN Annex 26 30 31 34 205 27 226 206 208 90 116 112 124 125 129 131 70 78 95 56 186 187 134 135 221 57 83 224 150 103 105 210 212 216 7 155 207 215 Fig 15 2 Regulator DN 15 to 50 with external s...

Page 67: ...subsidiaries representatives and service facilities worldwide can be found on our website u www samsongroup com or in all SAMSON product catalogs Required specifications Please submit the following d...

Page 68: ...15 6 EB 3226 EN Annex...

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Page 72: ...2021 10 20 English SAMSON AKTIENGESELLSCHAFT Weism llerstra e 3 60314 Frankfurt am Main Germany Phone 49 69 4009 0 Fax 49 69 4009 1507 samson samson de www samson de EB 3226 EN...

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