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EB 2546-1 EN

Malfunctions

Table 4:

Troubleshooting

Malfunction

Possible reasons

Recommended action

Downstream pressure

hunts

Regulator too large

Check the sizing.

Change K

coefficient, if necessary or install

a different sized regulator.

The restriction in the control line

for pressure tapping is missing.

Install a restriction.

Contact SAMSON's After-sales Service.

Loud noises

High flow velocity, cavitation

Check the sizing.

Install larger regulator, if necessary.

Leakage at the actuator

Defective operating diaphragm

and backup diaphragm

Replace damaged diaphragms.

Contact SAMSON's After-sales Service.

Leakage at the

diaphragm stem

Bellows seal on the diaphragm

stem defective

Replace the diaphragm stem with bellows seal.

Contact SAMSON's After-sales Service.

Red mark appears at the

diaphragm rupture

indicator.

Defective operating diaphragm

Replace damaged diaphragm.

Contact SAMSON's After-sales Service.

Risk of TÜV approval (based on AGFW worksheet FW 504) for Type 36-3 becoming void.

Consult SAMSON's After-sales Service before you change parts or perform service or repair

work on TÜV-tested Type 36-3 Regulators.

NOTICE

Содержание 36-3

Страница 1: ...Translation of original instructions EB 2546 1 EN Edition November 2018 Type 36 3 Safety Shut off Valve SSV with pressure reducing valve ...

Страница 2: ... 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 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 i...

Страница 3: ...ting and storage 17 4 2 1 Transport 18 4 2 2 Lifting 18 4 2 3 Storage 20 5 Installation 21 5 1 Preparation for installation 21 5 2 Checking the installation conditions 21 5 3 Additional fittings 22 6 Start up and operation 24 6 1 Start up 24 6 1 1 Installing the regulator 24 6 1 2 Pipeline flushing 25 6 1 3 Pressure test 25 6 2 Adjusting the set point 26 7 Maintenance 27 7 1 Preparation for return...

Страница 4: ...4 EB 2546 1 EN ...

Страница 5: ...al forces or any other external factors Î Refer to the technical data and nameplate for limits and fields of application as well as possible uses Reasonably foreseeable misuse The regulators are not suitable for the following applications Use outside the limits defined during sizing and by the technical data Use outside the limits defined by the accessories mounted on the regulator Furthermore the...

Страница 6: ...rs and operating personnel must prevent hazards that could be caused in the regulator by the process medium the operating pressure the signal pressure or by moving parts by taking appropriate precautions They must observe all hazard statements warning and caution notes in these mounting and oper ating instructions especially for installation start up and service work We also recommend checking the...

Страница 7: ...ropean 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 This EU declaration of conformity is included in the Annex of these instructions see section 10 2 According to the ignition risk assessment performed in accordance with EN 13463 1 2009 section 5 2 the non elect...

Страница 8: ...l injury due to preloaded springs Regulators in combination with preloaded set point springs are under tension These regulators can be identified by the red warning label on the actuator s set point springs Î Before starting any work on the springs relieve the compression from the preloaded springs Î Only use the SAMSON disassembly tool 1280 4052 Crush hazard arising from moving parts The regulato...

Страница 9: ...nce reach regulation 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 burns Î If possible drain the process medium from all the plant sections concerned and the regulator Î Wear protective clothing safety gloves and eyewear Risk of burn injuries d...

Страница 10: ...e pressure for regulator and plant 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 Risk of leakage and regulator damage due to excessively high or low tightening torques Observe the specified torques on tightening regulator co...

Страница 11: ...er with index 3 Configuration ID 4 Order number or date 5 KVS coefficient 6 Set point range 7 Valve size 8 Nominal pressure 9 Perm differential pressure 10 Perm temperature 11 Body material Fig 1 Nameplate The nameplate of all sizes is affixed to the body flange see Fig 2 Nameplate position on the body Fig 2 Nameplate on the body flange ...

Страница 12: ... rate and as a result the pressure ratio across the valve The plug stem is sealed by a frictionless bellows 8 The downstream pressure p2 to be controlled is transmitted over the control line 12 to the operating di aphragm 11 1 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...

Страница 13: ...Seat 3 Plug 4 Plug stem 5 Balancing bellows 6 Set point adjuster 7 Set point springs 8 Bellows seal 9 Nut 10 Crossbeam 11 Actuator housing 11 1 Operating diaphragm 11 2 Backup diaphragm 11 3 Diaphragm rupture indicator 11 4 Intermediate piece 12 Control line 13 Restriction Fig 3 Functional diagram View drawn turned by 90 ...

Страница 14: ...petested as a safety shut off valve SSV by the German Technical Inspectorate TÜV according to the require ments stipulated by AGFW German District Heating Association The test mark is available on request Temperature range The Type 36 3 Regulator is designed for a temperature range from 0 to 150 C Leakage class The regulator has the leakage class I accord ing to IEC 60534 4 Noise emission SAMSON i...

Страница 15: ...issible temperature 150 C Max permissible ambient temperature 80 C Set point ranges bar 2 0 to 4 2 2 4 to 6 3 6 0 to 10 5 Leakage class according to IEC 60534 4 0 05 of KVS coefficient Compliance Table 2 Materials Material numbers according to DIN EN Valve Pressure rating PN 16 PN 25 PN 40 Body Cast iron EN GJL 250 Spheroidal graphite iron EN GJS 400 18 LT Cast steel 1 0619 Seat Stainless steel Pl...

Страница 16: ...50 65 80 100 Length L 130 150 160 180 200 230 290 310 350 Height H 415 470 600 615 Height Forged steel H2 53 70 92 98 128 Other materials 44 72 98 118 Diaphragm housing ØD 170 mm A 80 cm Length LM 30 mm Weight Weight for PN 16 1 approx kg 13 0 14 0 14 5 20 0 22 0 25 5 41 5 48 5 57 5 1 10 for spheroidal graphite iron EN GJS 400 18 LT PN 25 and cast steel 1 0619 PN 40 ...

Страница 17: ... packaging until immedi ately before installation Proceed as follows to lift and install the regu lator 1 Remove the packaging from the control ler 2 Dispose of the packaging in accordance with the valid regulations NOTICE Note 4 2 Transport lifting and storage Hazard due to suspended loads falling Stay clear of suspended or moving loads Risk of lifting equipment tipping and risk of damage to lift...

Страница 18: ...ings Repair any damage immediately Protect the regulator against moisture and dirt Observe the permissible ambient tem peratures see section 3 1 4 2 2 Lifting To install a large regulator into the pipeline use lifting equipment e g crane or forklift to lift it Lifting instructions Secure slings against slipping Make sure the slings can be removed af ter installation Prevent the regulator from tilt...

Страница 19: ... 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 section 5 5 After installation in the pipeline check whether the regulator flanges are bolted tight 6 Remove slings We recommend using a hook with safety latch see Fig 5 The safety latch prevents the slings from slipping during lifting and transporting Tip...

Страница 20: ...egulators is 20 to 65 C 4 to 149 F Do not place any objects on the regulator Special storage instructions for elastomers Elastomer e g actuator diaphragm We recommend a storage temperature of 15 C 59 F for elastomers SAMSON s After sales Service can provide more detailed storage instructions on re quest Tip Standard mounting position Alternative mounting position for liquids up to 80 C Fig 6 Mount...

Страница 21: ...peline medium temperature etc Î Check any mounted pressure gauges to make sure they function Note Note 5 2 Checking the installation conditions Pipeline routing and mounting position Î Install the actuator housing with the set point springs suspended downward in horizontal pipelines see section Fig 6 Î Install a strainer upstream of the regula tor see section 5 3 Î Make sure the direction of flow ...

Страница 22: ... strainer to permanently filter the process medium Select a strainer mesh size suitable for the process medium Allow sufficient space to remove the filter Observe the flow direction In horizontal pipelines the filter element faces downward Install strainers in vertical pipelines with the medium flowing upward with the drain plug facing upward Check the strainer at regular intervals and clean it if...

Страница 23: ...lator must not yet be insulated at this stage 1 Start up the plant and adjust the set point 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 the control line is to be routed through the insulation special care must be taken with the seali...

Страница 24: ... down or heat up to reach ambient temperature before start up 7 Slowly open the shut off valve in the pipeline after the valve has been in stalled 6 Start up and operation 6 1 Start up Re Risk of personal injury due to process me dium escaping under pressure First start up the regulator after mounting all parts Crush hazard arising from moving parts Do not insert hands or fingers into the set poin...

Страница 25: ...peline proceed as de scribed in Table 4 6 1 3 Pressure test Risk of the operating diaphragm bursting due to excessive pressure during pressure testing The pressure must not exceed the maxi mum permissible pressure by 1 5 times the pressure rating Remove the control line from the regulator and seal the open connection with a blank ing plug accessories blanking plug 8323 0030 and seal 8412 0771 The ...

Страница 26: ... suitable end plugs Alternative ly install a shut off valve in the control line Make sure that the pressure rises simulta neously upstream and downstream of the regulator to avoid damaging the balanc ing bellows Do not allow the pressure to exceed the 1 5 times the nominal pressure of the valve body The valve must remain open Therefore set the maximum set point to ensure that the regulator does no...

Страница 27: ...roved by SAMSON WARNING NOTICE NOTICE NOTICE 7 Maintenance The regulator does not require any mainte nance Nevertheless it is subject to natural wear particularly at the seat plug and oper ating diaphragm Depending on the operat ing conditions check the regulator at regular intervals to avoid possible malfunctions Risk of bursting in pressure equipment Regulators and pipelines are pressure equip m...

Страница 28: ...f regulator damage due to the use of unsuitable lubricants Only use lubricants approved by SAMSON SAMSON s After sales Service can support you concerning lubricant tightening torques and tools approved by SAMSON 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 pro...

Страница 29: ...plest case the functioning can be restored following the recommended action Special tools may be required for re pair work Exceptional operating and installation condi 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 accoun...

Страница 30: ... has been triggered ÎCheck plant Unlock safety device Strainer blocked ÎClean strainer Downstream pressure exceeds the adjusted set point Foreign particles blocking the plug ÎRemove foreign particles ÎReplace damaged parts ÎContact SAMSON s After sales Service Seat and plug are worn or leak ÎClean the seat and plug ÎReplace the damaged seat and plug ÎContact SAMSON s After sales Service Regulator ...

Страница 31: ...sary Leakage at the actuator Defective operating diaphragm and backup diaphragm ÎReplace damaged diaphragms ÎContact SAMSON s After sales Service Leakage at the diaphragm stem Bellows seal on the diaphragm stem defective ÎReplace the diaphragm stem with bellows seal ÎContact SAMSON s After sales Service Red mark appears at the diaphragm rupture indicator Defective operating diaphragm ÎReplace dama...

Страница 32: ...ssioning and removal Risk of bursting in pressure equipment Regulators and pipelines are pressure equip ment Improper opening can lead to bursting of the regulator Before starting any work on the regulator depressurize all plant sections concerned as well as the regulator Drain the process medium from all the plant sections concerned as well as the regulator Wear personal protective equipment Risk...

Страница 33: ...be found on our website u www samson de or in all SAMSON product catalogs To assist diagnosis and in case of an unclear mounting situation specify the following de tails so far as possible See section 2 Device type and nominal size Model number and configuration ID Upstream and downstream pressure Temperature and process medium Min and max flow rate Is a strainer installed Installation drawing sho...

Страница 34: ...ype Examination Certificate Modul B Module B Zertifikat Nr Certificate no 01 202 931 B 13 0022 Angewandtes Konformitätsbewertungsverfahren Conformity assessment procedure applied Modul D Module D Zertifikat Nr Certificate no CE 0062 PED D SAM 001 16 DEU rev A Dem Entwurf zu Grunde gelegt sind Verfahren aus The design is based on the procedures specified in the following standards DIN EN 12516 2 DI...

Страница 35: ...EB 2546 1 EN 35 ...

Страница 36: ...2020 05 13 English SAMSON AKTIENGESELLSCHAFT Weismüllerstraße 3 60314 Frankfurt am Main Germany Phone 49 69 4009 0 Fax 49 69 4009 1507 samson samson de www samson de EB 2546 1 EN ...

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