Samson 2335 Service manual

Translation of original instructions

EB 2552-2 EN

Type2335 Excess Pressure Valve with Pilot Valve

Self-operated Regulators

Edition July 2021

Definition 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

EB 2552-2 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. The images shown in

these instructions are for illustration purposes only. The actual product may vary.

ÎFor the safe and proper use of these instructions, read them carefully and keep them for

later reference.

ÎIf you have any questions about these instructions, contact SAMSON‘s After-sales Service

(aftersalesservice@samsongroup.com).

Documents relating to the device, such as the mounting and operating

instructions, are available on our website at www.samsongroup.com >

Service & Support > Downloads > Documentation.

Contents

EB 2552-2 EN

1 General safety instructions.............................................................................4

2 Process medium and scope of application.......................................................5

2.1 Transportation and storage.............................................................................5

3 Design and principle of operation ..................................................................6

4 Installation....................................................................................................9

4.1 Notes on installation ......................................................................................9

4.2 Strainers .....................................................................................................10

4.3 Shut-off valve...............................................................................................10

4.4 Pressure gauge ............................................................................................10

5 Operation...................................................................................................12

5.1 Start-up.......................................................................................................12

5.2 Pressure test.................................................................................................12

5.3 Steam applications.......................................................................................13

5.4 Adjusting the set point..................................................................................13

5.5 Decommissioning.........................................................................................13

6 Maintenance ...............................................................................................14

7 Nameplate..................................................................................................18

8 Technical data .............................................................................................19

9 Dimensions .................................................................................................21

10 After-sales service .......................................................................................23

4 EB 2552-2 EN

General safety instructions

1 General safety instructions

− The device must be mounted, started up or serviced by fully trained and

qualiedpersonnelonly;theacceptedindustrycodesandpracticesareto

be observed. Make sure employees or third parties are not exposed to any

danger.

− All safety instructions and warnings given in these mounting and operating

instructions, particularly those concerning installation, start-up, and mainte-

nance, must be strictly 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 dangers due to their specialized training, their

knowledge and experience as well as their knowledge of the applicable

standards.

− 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 EU declaration of conformity can be

provided on request.

− To ensure appropriate use, only use the regulator in applications where the

operatingpressureandtemperaturesdonotexceedthespecicationsused

for sizing the regulator at the ordering stage.

− The manufacturer does not assume any responsibility for damage caused by

external forces or any other external factors.

− Any hazards that could be caused in the valve by the process medium, op-

erating pressure or by moving parts are to be prevented by taking appropri-

ate precautions.

− Proper transport, storage, installation, operation and maintenance are as-

sumed.

EB 2552-2 EN 5

Process medium and scope of application

2 Process medium and scope of

application

Pressure regulators for set points from 2 to

28bar·ValvesizesDN65to400·Pressure

ratingPN16to40·Suitableforliquids,

gasesandvaporsupto350°C

The differential pressure across the regulator

is used as auxiliary energy to operate the

valve. To open the regulator, this pressure

must be at least as high as the minimum dif-

ferentialpressure∆pminspeciedinTable1.

The attached pilot valve (acting as an excess

pressure valve) determines the function of the

regulator.

Risk of uncontrolled excess pressure in the

plant.

Risk of bursting

If necessary, a suitable overpressure

protection must be installed on site in the

plant section.

WARNING

2.1 Transportation and storage

The device must be carefully handled, trans-

ported and stored. Protect the regulator

againstadverseinuences,suchasdirt,

moisture or temperature outside the ambient

temperature range.

Do not remove the protective caps from the

valve ports until immediately before install-

ing the valve into the pipeline.

When regulators are too heavy to be lifted

by hand, fasten the lifting equipment to a

suitable place on the valve body.

Do not attach lifting slings or lifting equip-

ment to mounting parts, such as control

line, pilot valve etc.

The valve can fall or mounting parts may be

damaged.

Securely fasten slings or lifting equipment to

the valve body and secure against slipping.

WARNING

6 EB 2552-2 EN

Design and principle of operation

3 Design and principle of oper-

ation

See Fig.1 and Fig.2.

Themediumowsthroughtheglobevalve

(1) in the direction indicated by the arrow.

Thepositionoftheplugdeterminestheow

rate across the area released between plug

(3) and seat (2). The travel position of the pi-

lot valve (5) determines the pressure condi-

tions across the valve.

The forces created by the upstream pressure

p1acting on the plug surface and by the

control pressure pSacting on the balancing

bellows (4) or balancing diaphragm (11)

and the force of set point spring (3.1) are

compared.

IntheType2335ExcessPressureValve,the

rising upstream pressure p1causes the main

valve to open. Together with the pilot valve,

theVenturinozzle(8)(thexedrestriction

(6) and needle valve (9) in the version for

steam) create the control pressure pS.

When the pilot valve is closed, the valve is

fully balanced. The control pressure pSbe-

tweenthepilotvalveandVenturinozzleact-

ing on the outside of the balancing bellows

(4) or balancing diaphragm (11) and the

upstream pressure p1balance each other out

(pS= p1). The set point spring below the plug

closes the valve.

When the pilot valve opens, the control pres-

sure pSfalls, causing the differential pressure

at the balancing bellows or balancing dia-

phragm to increase. The force acting on the

plug surface opposes the force of the springs

and the valve opens.

To ensure proper functioning, the minimum

differentialpressure∆pmin must be available

asspecieddependingontheeldofappli-

cation.

The regulator version for steam is only avail-

able with valves balanced by a bellows. This

version has a compensation chamber (10)

alreadyttedinthecontrolline.Theneedle

valve (9) is open and lead-sealed.

Beforestart-up,llthecompensationcham-

berwithwateratthetoplleropening.

Table1: Minimum differential pressure ∆pmin

Valve size DN65 DN80 DN100 DN125 DN150 DN200 DN250 DN300 DN400

Minimum differential

pressure∆pmin

Valvebalancedby

a bellows for steam

applications 0.2bar(640cm²actuator)

0.4bar(320cm²actuator)

1.9bar 2.0bar 1.4bar 1.4bar – –

Valvebalancedby

a bellows for air/

water

1.0bar 1.0bar 0.7bar 0.7bar – –

Valvebalancedby

a diaphragm –0.8bar 0.8bar 0.4bar 0.4bar 0.5bar 0.3bar

EB 2552-2 EN 7

Design and principle of operation

Type2335ExcessPressureValve·Type2422Valvebalanced by a bellows·DN125 to 250

3.1

p1p2

5.1

Type 2422 as main valve balanced by a bellows

Bottom section

with bellows

Pilot valve

Versionsuitableforvapors

5.1

Pilot valve

Bottom section

with bellows

Versionsuitableforliquidsandgases

1 Globe valve (main valve)

2 Seat

3 Plug with plug stem

3.1 Set point spring

4 Balancing bellows

5 Pilot valve

5.1 Control line for pilot valve

6Venturinozzle(forgasesand

liquids)

7 Strainer

8 Fixed restriction (version for steam)

9 Needle valve (version for steam)

10 Compensation chamber (only for steam or

mediumtemperaturesabove150°C)

pSControl pressure

p1Upstream pressure

p2Downstream pressure

Fig.1: Functional diagram of valve balanced by a bellows

8 EB 2552-2 EN

Design and principle of operation

Type2335ExcessPressureValve·Type2422Valve,balanced by a diaphragm·DN125to400

1233.1 11

p1p

5.1

Diaphragm section

Type2422 as main valve, balanced by a diaphragm

Pilot valve

1Valvebody(mainvalve)

2 Seat

3 Plug with plug stem

3.1 Set point spring

5 Pilot valve

5.1 Control line for pilot valve

6Venturinozzle

7 Strainer

11 Balancing diaphragm

pSControl pressure

p1Upstream pressure

p2Downstream pressure

Fig.2: Functional diagram of valve balanced by a diaphragm

EB 2552-2 EN 9

Installation

4 Installation

See Fig.3.

Select the installation location making sure

that the regulator is installed at a distance of

at least six times the valve size (DN) away

frompipettingsorinstrumentsthatcause

owturbulence(e.g.pipebends,manifolds,

pressure measuring points or other valves).

Theycanchangetheowconditionswhich

may lead to an instable control process es-

pecially in applications with gases, air or

steam.

Contact SAMSON to obtain the

TV-SK17041documentationwhichcontains

more details on installation requirements.

4.1 Notes on installation

Install the ready-assembled regulator in hori-

zontal pipelines.

− Flush and clean the pipeline thoroughly

before installing the regulator.

Otherwise, impurities in the pipeline may

impair the proper functioning of the

valve, above all the tight shut-off.

− Thedirectionofowmustmatchthedi-

rection indicated by the arrow on the

body.

− Install the regulator free of stress. If nec-

essary, support the pipeline near to the

connectinganges.Donotattachsup-

ports directly to the valve or actuator.

− Install a strainer upstream of the regula-

tor.

− Protect the regulator from icing up when

controlling media that can freeze. If nec-

essary, depressurize and drain the regu-

lator and remove it from the pipeline

while the plant is shut down.

The side on which the operating elements

(hook-up of the pilot valve) are located var-

ies depending on whether a valve balanced

by a bellows or a diaphragm is used.

Mounting orientation

Observetheowdirection.

Valve balanced by a bellows

− Bellows including housing

suspended downward.

Valve balanced by a diaphragm

− Balancing diaphragm (diaphragm sec-

tion) pointing upward

Insulation ·Toinsulatecoldsystems,we

recommendrstllingtheplantandcarefully

rinsingit(seesection5.1).Theregulator

must not be insulated until the set point is

adjusted.

− Start up the plant and adjust the set

point. Shut down the plant again and let

it heat up until the condensation water

has dried off.

− Afterwards, insulate the regulator and

pipes conveying the process medium us-

ing insulation material with a water va-

por barrier. If the pilot valve has a

spring, it must must be protected by a

sleeve to allow it to move. The

spring-loaded actuator stem must not

touch the insulation.

Note



10 EB 2552-2 EN

Installation

Thermal insulation

Do not insulate the pilot valve as well in ap-

plications with medium temperatures above

80°C.

Pipeline routing

The inlet and outlet lengths vary depending

on several variables and process conditions

and are intended as recommendations. Con-

tactSAMSONifthelengthsaresignicantly

shorter than the recommended lengths.

To ensure that the regulator functions proper-

ly, proceed as follows:

ÎObserve the inlet and outlet lengths (see

Table2).ContactSAMSONiftheregula-

tor conditions or state of the medium

process deviate.

ÎInstall the regulator free of stress and

with the least amount of vibrations as

possible.

ÎFor media with a tendency to conden-

sate, install the pipeline with a slight

downward slope on both sides so that

the condensate can drain properly. If the

pipeline upstream and downstream of

the regulator run vertically upwards, an

automatic drainage is required.

ÎInstalltheregulatorallowingsufcient

space to remove the actuator and valve

or to perform service work on them.

Pressure testing of the plant·Thepressure

must not exceed the maximum permissible

pressure of the regulator and plant on testing

Note

the pressure of the plant when the regulator

is already installed. An excessive test pres-

sure can damage the balancing bellows or

diaphragm. If necessary, remove the regula-

tor from the pipeline or isolate the regulator

in the pipeline and install a bypass.

4.2 Strainers

Installastrainer(e.g.SAMSONType1/

Type2)upstreamoftheexcesspressure

valve.

− Thedirectionofowmustcorrespondto

the arrow on the body.

− Do not use the strainer to permanently

ltertheprocessmedium.

− Thelterelementmustbeinstalledto

hang downwards or sideways for appli-

cations with steam.

Remember to leave enough space to remove

the lter element.

4.3 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.

4.4 Pressure gauge

Install a pressure gauge both upstream and

downstream of the regulator to monitor the

pressures prevailing in the plant.

Tip

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