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EB 2540 EN

1-7

Safety instructions and measures

NOTICE

Risk of leakage and regulator damage due to excessively high or low tightening

torques.

Observe the specified torques when tightening regulator components. Excessive tight

ening torques lead to parts wearing out more quickly. Parts that are too loose may

cause leakage.

Observe the specified tightening torques (see 'Tightening torques' in Annex).

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

Certain tools are required to work on the regulator.

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

Risk of the process medium being contaminated through the 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.

Risk of excess pressure damaging plant sections due to construction-related seat

leakage through the regulator.

Always install a safety device (e.g. safety excess pressure valve or safety relief

valve) in the plant.

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

Note

Содержание 2404-2

Страница 1: ...Translation of original instructions EB 2540 EN Type 2404 2 Excess Pressure Valve with Pilot Valve Self operated regulator for small set point ranges Edition May 2023...

Страница 2: ...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 For the...

Страница 3: ...3 3 Type 2420 Actuator 2 5 2 3 4 Type 2406 Pilot Valve 2 5 2 3 5 Type 2441 Input Pressure Regulator 2 5 3 Design and principle of operation 3 1 3 1 Additional fittings 3 3 3 2 Technical data 3 4 4 Sh...

Страница 4: ...regulator after service work 9 3 9 3 Service work 9 3 9 4 Ordering spare parts and operating supplies 9 4 10 Decommissioning 10 1 11 Removal 11 1 11 1 Removing the regulator from the pipeline 11 1 11...

Страница 5: ...AMSON 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 Refer...

Страница 6: ...e plant operators and operating personnel must prevent hazards that could be caused in the regulator by the process medium the operating pressure or by moving parts by taking appropriate precautions P...

Страница 7: ...uct defined in the 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...

Страница 8: ...s 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 open...

Страница 9: ...incorrect nameplates or labels 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 b...

Страница 10: ...lid particles in the pipeline The plant operator is responsible for cleaning the pipelines in the plant Flush the pipelines before start up Risk of regulator damage due to the use of unsuitable lubric...

Страница 11: ...required to work on the regulator Only use tools approved by SAMSON When in doubt consult SAMSON Risk of the process medium being contaminated through the use of unsuitable lubri cants and or contamin...

Страница 12: ...1 8 EB 2540 EN Safety instructions and measures...

Страница 13: ...point range 7 Valve size 8 Pressure rating 9 Perm differential pressure 10 Perm temperature 11 Body material 12 Serial number if applicable 13 T V registration no if exists 14 Data Matrix code 15 CE m...

Страница 14: ...e at actuator 7 Valve size 9 Set point range 10 Diaphragm material 11 Country of origin 12 UKCA if applicable 13 Year of manufacture 14 Month of manufacture 15 CE marking 1 Max perm operating pressure...

Страница 15: ...nufacture 4 Type designation 5 Thread size valve size DIN DN ANSI NPS JIS DN A B 6 Flow coefficient DIN KVS ANSI CV JIS CV 7 Perm temperature DIN C ANSI F JIS C F 8 Set point range DIN bar ANSI psi JI...

Страница 16: ...ation of the nameplates Location of the nameplate on the main valves Location of the nameplate on the input pressure regulator Location of the nameplate on the pilot valve Fig 2 5 Nameplates of the ma...

Страница 17: ...etails on the nameplate see sec tion 2 1 2 3 3 Type 2420 Actuator Specifying the material number you can contact us to find out which material is used It is specified on the nameplate in the MNo field...

Страница 18: ...2 6 EB 2540 EN Markings on the device...

Страница 19: ...valve over the control line 2 4 The force created by the upstream pressure p1 at the operating diaphragm 2 2 is compared with the adjusted spring force of the set point spring The pilot valve opens wh...

Страница 20: ...ing 1 2 Operating diaphragm main valve 2 Pilot valve 2 1 Set point spring 2 2 Operating diaphragm pilot valve 2 3 Set point adjuster screw SW 27 11 8 2 4 Control line 2 5 Cap 3 Input pressure regulato...

Страница 21: ...the regula tor Do not use the strainer to permanently filter the process medium Select a strainer mesh size suitable for the process medium Any impurities carried along by the process medium may impa...

Страница 22: ...pressure to an adjusted set point For gases Medium temperature range 5 to 195 F 20 to 90 C Set points 0 075 to 3 psi 5 to 200 mbar Valve sizes NPS 2 to 16 DN 65 to 400 Pressure rating Class 125 150 3...

Страница 23: ...differential pressure p 175 psi 12 bar Perm temperature 5 to 195 F 20 to 90 C 1 Conformity Type 2422 as main valve balanced by a diaphragm with Type 2420 Actuator Valve size NPS 8 DN 200 NPS 10 DN 250...

Страница 24: ...si 25 to 60 mbar 0 75 to 3 psi 50 to 200 mbar Actuator area 100 in 640 cm 50 in 320 cm 50 in 320 cm 50 in 320 cm Input pressure pe Fixed setting by input pressure regulator min 15 psi 1 bar Perm tempe...

Страница 25: ...el body Actuator springs 1 4310 3 Type 2422 Valve main valve with Type 2420 Actuator Body A126B A216 WCC A351 CF8M EN GJL 250 1 0619 1 4408 Valve seat and plug NPS 8 to 10 DN 200 to 250 CF3M 1 4409 NP...

Страница 26: ...ns for sour gas service NACE possible Table 3 6 Materials for input pressure regulator Material numbers according to ASTM and DIN EN Input pressure regulator Type 2441 Body 1 4408 A351 CF8M Valve seat...

Страница 27: ...2 5 317 mm L3 approx 9 4 240 mm 8 3 212 mm D 5 to 15 mbar 0 075 to 0 2 psi 15 380 mm A 100 in 640 cm 10 to 30 mbar 0 15 to 0 45 psi 11 2 285 mm A 50 in 320 cm 25 to 60 mbar 0 35 to 1 5 psi 11 2 285 mm...

Страница 28: ...12 3 313 mm 13 5 343 mm D 0 075 to 0 2 psi 5 to 15 mbar 15 380 mm A 100 in 640 cm 0 15 to 0 45 psi 10 to 30 mbar 11 2 285 mm A 50 in 320 cm 0 35 to 1 5 psi 25 to 60 mbar 11 2 285 mm A 50 in 320 cm 0...

Страница 29: ...d principle of operation D H H3 B L3 L1 L2 Pipe Supply pressure p Pipe Control line for upstream pressure p1 Pipe Supply pressure p Dimensions Fig 3 3 DN 65 to 100 NPS 2 to 4 Versions with seal diaphr...

Страница 30: ...gn and principle of operation H3 H L1 D L3 L2 Pipe Supply pressure p Pipe Supply pressure p Pipe Control line for upstream pressure p1 Dimensions Fig 3 4 DN 125 to 150 NPS 6 Versions with seal diaphra...

Страница 31: ...esign and principle of operation H3 H L1 D L3 L2 Pipe Supply pressure p Pipe Control line for upstream pressure p1 Pipe Supply pressure p Dimensions Fig 3 5 DN 125 to 150 NPS 6 Versions with seal diap...

Страница 32: ...tion D H H3 B L3 L1 L2 Dimensions Pipe Supply pressure p Pipe Control line for upstream pressure p1 Pipe Supply pressure p Pipe Control line for upstream pressure p1 Fig 3 6 DN 200 to 400 NPS 8 to 16...

Страница 33: ...ration H H3 B D L3 L1 L2 Pipe Supply pressure p Pipe Control line for upstream pressure p1 Pipe Supply pressure p Pipe Control line for upstream pressure p1 Dimensions Fig 3 7 DN 200 to 300 NPS 8 to 1...

Страница 34: ...3 16 EB 2540 EN Design and principle of operation...

Страница 35: ...e 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 prin...

Страница 36: ...15 to max 55 kg taking into account age gender and physical fitness Observe the occupational health and safety regulations valid in the country of use DANGER WARNING WARNING Risk of personal injury d...

Страница 37: ...ing work for longer periods of time Make sure that the axis of the pipeline is always horizontal during lifting and the axis of the plug stem is always vertical Lifting 1 Attach one sling to the flang...

Страница 38: ...gs Repair any damage immediately Protect the regulator 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...

Страница 39: ...shorter than the recommended lengths To ensure that the regulator functions proper ly proceed as follows Install the regulator allowing sufficient space to remove the actuator and valve or to perform...

Страница 40: ...nting position the valve actuator and pipeline must be supported or suspended Note Do not attach supports directly to the valve actuator or control line NOTICE 4 3 4 4 4 3 1 2 4 1 4 2 Tank 1 Shut off...

Страница 41: ...ady during installation work Flush the pipeline before installing the regulator The plant operator is responsible for cleaning the pipelines in the plant Check any mounted pressure gauges to make sure...

Страница 42: ...the valve The arrow on the valve indicates the direction of flow 5 Make sure that the correct flange gaskets are used 6 Bolt the pipe to the valve free of stress 7 Fasten the supply line pipe to the i...

Страница 43: ...ions Wear hearing protection when working 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 componen...

Страница 44: ...tor components If necessary shut off the control lines on performing a pressure test on the main valve Make sure that the pressure rises simulta neously upstream and downstream of the regulator to avo...

Страница 45: ...ur during operation caused by the process medium and the operating condi tions Wear hearing protection when working near the valve WARNING WARNING WARNING Re Risk of personal injury due to process me...

Страница 46: ...m up to reach ambient temperature before start up 2 Slowly open the shut off valve in the sup ply pipeline Slowly opening these valves prevents a sudden surge in pressure and high flow velocities whic...

Страница 47: ...perating condi tions Wear hearing protection when working near the valve WARNING WARNING WARNING 7 1 Adjusting the set point Adjust the set point by tensioning the set point springs 2 1 at the set poi...

Страница 48: ...e will even remain stuck in the closed position 3 Monitor the set point pressure to be ad justed at the pressure gauge on the up stream pressure side When the upstream pressure reaches the set point p...

Страница 49: ...m of the main valve defective Replace the balancing diaphragm with a new one Install a shut off valve instead of the pilot valve If the main valve does not open when the shut off valve is opened the m...

Страница 50: ...le Raise upstream pressure or reduce downstream pressure Set point range of the pilot valve is too low Convert or replace pilot valve Main valve seized up Clean main valve Install a shut off valve ins...

Страница 51: ...S CV coefficient Periodic excitation to vibrate originating from the plant Contact SAMSON Possibly change the natural frequency e g over a needle valve when there is resonance in the plant Contact SAM...

Страница 52: ...event of a regulator malfunction 1 Close the shut off valves to stop the pro cess medium from flowing through the regulator 2 Perform troubleshooting see sec tion 8 1 3 Rectify those malfunctions that...

Страница 53: ...u ries Allow components and pipelines to cool down or warm up to the ambient tem perature Wear protective clothing and safety gloves WARNING Risk of personal injury due to residual pro cess medium in...

Страница 54: ...se 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 9 1 Prepa...

Страница 55: ...ure the re quirements and conditions for start up or putting the valve back into operation are met 9 3 Service work Before performing any service work preparations must be made to the regu lator see s...

Страница 56: ...ON s After sales Service for infor mation on spare parts lubricants and tools Spare parts Contact SAMSON s After sales Service for more information on spare parts Lubricants Contact SAMSON s After sal...

Страница 57: ...ponents and the pipeline may become very hot or cold Risk of burn inju ries Allow components and pipelines to cool down or warm up to the ambient tem perature Wear protective clothing and safety glove...

Страница 58: ...r for service work or disassembly proceed as follows 1 Close the shut off valve 1 2 Depressurize the plant 3 Completely drain the pipelines and valve 4 If necessary allow the pipeline and reg ulator c...

Страница 59: ...medium can escape and depending on its properties may lead to personal in jury e g chemical burns Wear protective clothing safety gloves and eye protection Before removing the valve make sure the fol...

Страница 60: ...11 2 EB 2540 EN...

Страница 61: ...vices can be returned to SAMSON for repair Proceed as follows to return devices 1 Put the regulator out of operation see the Decommissioning section 2 Decontaminate the valve Remove any residual proce...

Страница 62: ...12 2 EB 2540 EN...

Страница 63: ...on al refuse regulations Do not dispose of components lubricants and hazardous substances together with your other household waste We can provide you with a recycling passport according to PAS 1049 on...

Страница 64: ...13 2 EB 2540 EN...

Страница 65: ...0 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...

Страница 66: ...CF8M NPS 1 2 Class 150 all fluids Control valve 3214 DIN EN body EN GJL 250 DN 65 125 PN 16 fluids G2 L2 L11 DIN EN body EN GJS 400 18 LT DN 50 80 PN 25 fluids G2 L2 L11 ANSI body A126 B NPS 3 4 Clas...

Страница 67: ...0 all fluids 42 2421 RS DIN EN body 1 0619 1 4408 1 4571 and 1 4401 1 4404 DN 32 50 PN 16 all fluids DIN EN body 1 0619 1 4408 1 4571 and 1 4401 1 4404 DN 32 40 PN 25 all fluids ANSI body A216 WCC A35...

Страница 68: ...of the laws of the Member States relating to the making available on the market of pressure equipment 2014 68 EU of 15 May 2014 Applied conformity assessment procedure for fluids according to Article...

Страница 69: ...y EN GJS 400 18 LT DN 100 150 PN 25 fluids G2 L2 L11 DIN EN body 1 0619 and 1 4408 DN 65 250 PN 16 all fluids DIN EN body 1 0619 and 1 4408 DN 50 250 PN 25 all fluids DIN EN body 1 0619 and 1 4408 DN...

Страница 70: ...PN 40 all fluids ANSI body A126 B NPS 6 16 Class 125 fluids G2 L2 L11 ANSI body A216 WCC und A351 CF8M NPS 2 16 Class 150 all fluids ANSI body A216 WCC und A351 CF8M NPS 2 10 Class 300 all fluids 2331...

Страница 71: ...the European Parliament and of the Council on the harmonization of the laws of the Member States relating to the making available on the market of pressure equipment 2014 68 EU of 15 May 2014 Applied...

Страница 72: ...14 8 EB 2540 EN...

Страница 73: ...SAMSON s After sales Service can support you concerning lubricants and sealants ap proved by SAMSON 15 3 Tools SAMSON s After sales Service can support you concerning tools approved by SAMSON 15 4 Ac...

Страница 74: ...be found on our website u www samsongroup com or in all SAMSON product catalogs Required specifications Please submit the following details Device type Type and nominal size of the main valve pilot v...

Страница 75: ......

Страница 76: ...2023 05 09 English SAMSON AKTIENGESELLSCHAFT Weism llerstra e 3 60314 Frankfurt am Main Germany Phone 49 69 4009 0 Fax 49 69 4009 1507 samson samsongroup com www samsongroup com EB 2540 EN EB 2540 EN...

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