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Samson 42-37, Монтаж и эксплуатация

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5-8 

 

EB 3017 EN

Installation

5.3 

Final installation

Tested SAMSON regulators are delivered as 

an assembled unit. In all other cases, the 
separate components (valve, actuator, con-
trol line and accessories) of the regulator are 
delivered separately. Upon delivery, the sep-
arate components must be assembled togeth-
er. The activities listed below are necessary 
for installation and before start-up of the 
regulator.

Risk of regulator damage due to exces-

sively high or low tightening torques.

Observe the specified torques when tighten

-

ing regulator components. Excessive tighten

-

ing torques lead to parts wearing out more 

quickly. Parts that are too loose may cause 
leakage.

 

Î

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

Risk of regulator damage due to the use of 

unsuitable tools.

 

Î

Only use tools approved by SAMSON 

(see 'Tools' in Annex).

Risk of regulator damage due to the use of 

unsuitable lubricants.

 

Î

Only use lubricants approved by 

SAMSON (see 'Lubricants' in Annex).

NOTICE

!

NOTICE

!

NOTICE

!

5.3.1 

Installing the regulator

Before installing the regulator, tighten the 
blanking plug(s) at the side of the valve body 
using a suitable box wrench (see 'Tightening 
torques' in the Annex).

The regulator can be installed into the down-

stream pressure pipe (return flow pipe) or 
the upstream pressure pipe (flow pipe) of the 
plant. See installation examples in Fig. 5-1.

1. 

Close the shut-off valves (1, 9) 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 
the flow direction through the valve. The 

arrow on the valve indicates the direction 

of flow.

4. 

Make sure that the correct flange gaskets 

are used.

5.  Bolt the pipe to the valve free of stress.

 

Î

Additional activities required for indi-

vidual components

6.  Mount the actuator.

 

−

Fasten the actuator on the valve by tight-

ening the coupling nut (11). Observe the 

alignment of the control line connection. 

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

Note

Содержание 42-37

Страница 1: ...slation of original instructions EB 3017 EN Type 42 37 Flow and Differential Pressure Regulator Type 42 39 Flow and Differential Pressure or Pressure Regulator Self operated Regulators Edition August...

Страница 2: ...contents of this part docu ment apply to the category specified after the number of the mounting and operating instruc tions e g EB xxxx followed by 03 0x indicating the category The part document onl...

Страница 3: ...sport 4 1 4 1 Accepting the delivered goods 4 1 4 2 Removing the packaging from the regulator 4 1 4 3 Transporting and lifting the regulator 4 2 4 3 1 Transporting the regulator 4 2 4 3 2 Lifting the...

Страница 4: ...regulator after service work 9 6 9 3 Service work 9 6 9 3 1 Replacing the actuator 9 7 9 3 2 Replacing the seat and plug 9 7 9 3 3 Replacing the actuator s operating diaphragm 9 7 9 4 Ordering spare p...

Страница 5: ...nly used in operating conditions that meet the specifications used for sizing the devices at the ordering stage In case operators intend to use the regulators in other applications or conditions than...

Страница 6: ...safety gloves and eye protection in applications with hot cold and or corrosive media Wear hearing protection when working near the valve Hard hat Safety harness when working at height Safety footwear...

Страница 7: ...ies of operating personnel Operating personnel must read and understand these mounting and operating instructions as well as the referenced documents and observe the specified hazard statements warnin...

Страница 8: ...ff 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 impro...

Страница 9: ...s medium escaping to the atmosphere Do not loosen the control line while the valve is pressurized Risk of personal injury due to loaded springs The set point springs of regulators with adjusted set po...

Страница 10: ...compliance reach regulation Risk of personal injury due to process medium escaping after an operating dia phragm bellows rupture When using the Type 42 39 Regulator as a pressure regulator residual pr...

Страница 11: ...re 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 surfaces Only use l...

Страница 12: ...guide 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 In...

Страница 13: ...r number or date 5 KVS CV 6 Set point range or spring range 7 Valve size 8 Pressure rating 9 Perm differential pressure 10 Perm temperature 11 Body material Nameplate of Type 2427 Actuator DIN ANSI ve...

Страница 14: ...ctuator 2 3 Material markings 2 3 1 Type 2423 Valve See the nameplate 11 for DIN ANSI ver sion body material For more details on the nameplate see section 2 1 2 3 2 Type 2427 and Type 2429 Actuators S...

Страница 15: ...by the upstream and downstream pressures that act on the plug are balanced out Type 42 37 The high pressure of p acts on the bottom diaphragm chamber D over the control line 18 The high pressure of th...

Страница 16: ...operation 1 1 2 1 3 1 1 2 3 4 19 18 21 B A C D V 8 5 7 12 1 9 13 1 13 2 15 12 2 16 17 11 1 4 Type 2423 Valve balanced by a bellows Type 2427 Actuator Fig 3 1 Functional diagram of Type 42 37 Regulato...

Страница 17: ...N 3 3 Design and principle of operation 19 20 18 B A C D V 21 22 Type 2423 Valve balanced by a bellows Type 2429 Actuator Fig 3 2 Functional diagram of Type 42 39 Regulator DN 15 to 250 with balancing...

Страница 18: ...Lock nut 1 3 Cap 1 4 Set point adjuster flow rate 2 Seat 3 Plug 4 Plug stem 5 Balancing bellows 5 1 Balancing diaphragm 7 Spring 8 Vent plug DN 125 and larger 9 Differential pressure spring 11 Coupli...

Страница 19: ...ainers We recommend installing a SAMSON strainer 2 upstream of the valve It prevents solid particles in the process medium from damaging the regulator Do not use the strainer to permanently filter the...

Страница 20: ...ressure and flow control Type 42 39 in the flow pipe Differential pressure and flow control Type 42 39 in the flow pipe Flow and pressure control V 3 7 V 3 7 V 4 7 pmin Minimum differential pressure a...

Страница 21: ...m 0 05 to 520 m h Valve size DN 15 to 250 Pressure ratings from PN 16 to 40 Note The regulator is open when relieved of pres sure The valve closes when the differential pressure pressure or flow rate...

Страница 22: ...or pressure set point ranges 0 1 to 0 6 bar 0 2 to 1 bar 0 5 to 1 5 bar 1 to 2 5 bar 2 to 5 bar 2 4 5 to 10 bar 2 Leakage class according to IEC 60534 4 0 05 of KVS coefficient Conformity Type 2423 V...

Страница 23: ...1 6 5 to 63 11 to 80 18 to 120 20 to 180 26 to 220 0 5 bar 0 15 to 3 0 25 to 4 5 0 4 to 5 3 0 6 to 9 5 0 9 to 16 2 to 24 3 5 to 40 6 5 to 55 11 to 90 18 to 120 20 to 180 26 to 260 30 to 300 Max permis...

Страница 24: ...lanced by a diaphragm Pressure rating PN 16 PN 25 PN 16 25 and 40 Valve body Cast iron EN GJL 250 Spheroidal graphite iron EN GJS 400 18 LT Cast steel 1 0619 Cast stainless steel 1 4408 Valve seat Red...

Страница 25: ...3 130 180 420 480 0 5 to 1 5 bar Height H 1 675 770 825 1130 1160 1240 Actuator D 225 mm A 160 cm 4 D 285 mm A 320 cm Weight 2 approx kg 20 5 21 22 28 5 29 31 5 45 50 63 135 185 425 485 1 to 2 5 bar H...

Страница 26: ...t H2 195 220 295 325 345 375 Weight for PN 16 1 in kg approx Type 2423 Valve 34 39 49 65 85 248 268 Type 2427 Actuator 16 27 35 1 PN 25 40 10 Dimensional drawings Type 2423 Valve balanced by a bellows...

Страница 27: ...orted 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 t...

Страница 28: ...l handling 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 persona...

Страница 29: ...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 30: ...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 31: ...he medium process deviate 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 F...

Страница 32: ...actuator and pipeline must be supported or suspended Do not attach supports directly to the valve or actuator Note NOTICE Standard mounting position suspended All versions Suitable for steam control...

Страница 33: ...n of the diaphragm chamber C remains open Control lines to be installed on site Type 42 37 and Type 42 39 Route the control line on site preferably using a 8x1 mm stainless steel pipe The control line...

Страница 34: ...e same height as the valve with the control line reaching at least from the mid axis of the pipeline valve to the actuator This allows the hot medium to cool down sufficiently see Fig 5 2 Depending on...

Страница 35: ...Connection at the top incorrect position Incorrect Connection at the bottom incorrect position M DN min 3 x DN min 3 x DN min 3 x DN DN Valve size Control line connection depending on how the pipe li...

Страница 36: ...aterial pres sure rating and temperature range match the plant conditions size and pressure rating of the pipeline medium temperature etc See the Markings on the device section for nameplate details T...

Страница 37: ...f process me dium Valve conditions Inlet length a Outlet length b Gas Ma 0 3 2 4 Vapors 1 Ma 0 3 2 4 Liquid Free of cavitation w 3 m s 2 4 Cavitation producing noise w 3 m s 2 4 1 No saturated steam F...

Страница 38: ...N see Lubricants in Annex NOTICE NOTICE NOTICE 5 3 1 Installing the regulator Before installing the regulator tighten the blanking plug s at the side of the valve body using a suitable box wrench see...

Страница 39: ...after the valve has been in stalled 5 3 2 Cleaning the pipeline We recommend additionally flushing the pipeline with installed regulator before start up Unscrew the control line 18 from the valve bod...

Страница 40: ...l injury due to process me dium escaping Do not start up the regulator until all parts have been mounted Risk of hearing loss or deafness due to loud noise Noise emission e g cavitation or flashing ma...

Страница 41: ...le for performing the pressure test SAMSON s After sales Service can support you to plan and perform a pressure test for your plant Risk of valve damage due to a sudden pressure increase and resulting...

Страница 42: ...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...

Страница 43: ...WARNING WARNING WARNING Re Risk of personal injury due to process me dium escaping Do not start up the regulator until all parts have been mounted Before start up or putting the valve back into servic...

Страница 44: ...w regulator into operation by slowly opening the shut off valves prefer ably starting from the return flow pipe Vent the bellows housing of valves bal anced by a bellows DN 125 and larger at the venti...

Страница 45: ...he operating condi tions Wear hearing protection when working near the valve WARNING WARNING WARNING 7 1 Adjusting the set point The control and shut off valves as well as all consumers or a bypass va...

Страница 46: ...or water Type 2423 Balanced by a bellows Valve size DN 15 20 25 32 40 50 65 80 100 125 150 200 250 Flow rate set point ranges for water in m h Diff pres sure across restriction prestriction 0 2 bar 0...

Страница 47: ...9 0 1 2 3 4 5 6 DN20 DN15 DN15 DN32 DN40 DN40 DN50 DN50 DN25 DN32 DN25 DN20 DN65 DN80 0 1 2 3 4 5 6 7 8 24 22 20 18 16 14 12 10 8 6 4 2 5 10 15 20 25 30 35 40 45 50 55 5 10 15 20 25 30 35 40 45 V m h...

Страница 48: ...0 325 300 275 250 225 200 125 80 10 70 20 50 30 60 40 90 100 110 120 DN200 DN250 DN200 DN250 DN200 DN250 DN150 DN100 DN125 V m h V m h V m h V m h 8 2 6 4 12 14 10 16 prestriction 0 5 bar ____ prestri...

Страница 49: ...0 180 200 0 2 4 6 8 10 12 14 16 18 V m h DN 125 DN 150 A 320 cm prestriction 0 2 bar balanced by a diaphragm DN 200 DN 250 0 50 100 150 200 250 300 350 400 450 0 2 4 6 8 10 12 14 16 18 20 m h V DN 200...

Страница 50: ...consumer at the reading of the installed pressure gauges If small differential pressure set points are to be adjusted we recom mend using a differential pressure gauge instead of the two pressure gaug...

Страница 51: ...tive operating diaphragm Replace damaged diaphragm Flow rate differential pressure or pressure set point not reached Regulator installed against the flow Install the regulator so that the direction of...

Страница 52: ...sure tapping is too large or missing Install a restriction Install a smaller restriction Do not completely close the needle valve Slow control response Restriction in the screw joint of the actuator d...

Страница 53: ...o 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 Plant operators are responsible for emergen cy action to be tak...

Страница 54: ...8 4 EB 3017 EN...

Страница 55: ...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 process medium in t...

Страница 56: ...es Service can support you in drawing up an inspection and test plan for your plant Note Tip Legend for Fig 9 1 to Fig 9 3 1 Valve body 1 1 Restriction 1 2 Lock nut 1 3 Cap 1 4 Set point adjuster flow...

Страница 57: ...1 2 1 3 1 1 2 3 4 19 18 21 B A C D V 8 5 7 12 1 9 13 1 13 2 15 12 2 16 17 11 1 4 Type 2423 Valve balanced by a bellows Type 2427 Actuator Fig 9 1 Functional diagram of Type 42 37 Regulator DN 15 to 2...

Страница 58: ...9 4 EB 3017 EN Servicing 19 20 18 B A C D V 21 22 Type 2423 Valve balanced by a bellows Type 2429 Actuator Fig 9 2 Functional diagram of Type 42 39 Regulator DN 15 to 250 with balancing bellows...

Страница 59: ...1 4 p1 18 p2 1 2 1 4 5 1 3 2 1 1 Type 2423 Valve balanced by a diaphragm Type 2427 Actuator for Type 42 37 or Type 2429 Actuator for Type 42 39 Fig 9 3 Functional diagram of Type 2423 Valve DN 65 to...

Страница 60: ...paration is completed Replace the actuator see section 9 3 1 Replace the seat and plug see sec tion 9 3 2 Replace the actuator s operating dia phragm see section 9 3 3 Tip 9 2 Installing the regulator...

Страница 61: ...r See Fig 9 1 to Fig 9 3 Removing the actuator 1 Put the regulator out of operation see the Decommissioning section 2 Unscrew the control line 18 to 20 3 Unscrew the coupling nut 11 of the dia phragm...

Страница 62: ...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 Lubricant Contact SAMSON s After sales Service for mor...

Страница 63: ...ponents and pipelines to cool down or warm up to the ambient tem perature Wear protective clothing and safety gloves DANGER WARNING Risk of personal injury due to pressurized components and process me...

Страница 64: ...ty gloves and eye protection 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 v...

Страница 65: ...orking 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 eye protection Bef...

Страница 66: ...11 2 EB 3017 EN...

Страница 67: ...After sales Service NOTICE NOTICE 2 Send an e mail u retouren samsongroup com to register the return shipment including the following information Type Material number Item numbers of accessories Origi...

Страница 68: ...12 2 EB 3017 EN...

Страница 69: ...EB 3017 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...

Страница 70: ...13 2 EB 3017 EN...

Страница 71: ...7 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 72: ...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 Stellger t aufgebrachte CE Zeichen hat keine G ltigkeit im Sinne der Druckger terichtlinie...

Страница 73: ...0 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 Stellger t aufgebrachte CE Zeichen hat keine G lt...

Страница 74: ...14 4 EB 3017 EN...

Страница 75: ...e 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 Accessories Table 15 2 Assignm...

Страница 76: ...21 Guide cap 22 Label 24 Compression spring 26 Guide tube 27 Bottom section 34 Flange 35 Screw plug 46 Graphite seal on metal core 51 Stud 52 Hex nut 81 Cap 82 Hex nut 132 O ring 171 Clamping ring 17...

Страница 77: ...EB 3017 EN 15 3 Annex 27 51 52 17 171 172 16 35 5 20 132 82 81 2 34 46 22 35 12 Fig 15 5 Type 2423 Valve DN 125 to 250 Balanced by a bellows...

Страница 78: ...ut 13 Washer 14 Plug stem 16 Seat 18 Plug 19 Screw 20 Body 21 Guide cap 22 Label 27 Cover 34 Ring 46 Seal 51 Stud 52 Hex nut 53 Screw plug 81 Nut 82 Hex nut 94 Stem 97 Hex nut self locking 27 51 52 14...

Страница 79: ...Plug 21 Nipple 24 Nut 38 Diaphragm plate 39 Diaphragm plate 42 Clamping disk 46 Seal 47 Diaphragm 49 Screw plug 50 Screw plug 51 Stud 52 Hex nut 53 Hex nut 54 Hex nut 57 O ring 6 29 52 51 21 47 50 11...

Страница 80: ...7 Screw joint with restriction 8 Diaphragm 10 12 Compression spring 15 Nameplate 18 Nipple 20 Diaphragm plate nut 21 Nut 26 28 Compression spring 29 Diaphragm stem 30 Diaphragm stem 32 Diaphragm plat...

Страница 81: ...EB 3017 EN 15 7 Annex 29 10 12 18 2 6 39 21 1 45 8 44 46 7 3 26 28 30 7 47 32 4 41 49 20 15 Fig 15 9 Type 2429 Diaphragm Actuator DN 15 to 250 Type 42 39...

Страница 82: ...tatives 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 details Device type and...

Страница 83: ......

Страница 84: ...2020 09 01 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 3017 EN...

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