Samson 2408 Service manual

Self-operated Pressure Regulators

Excess Pressure Valve

Type 2408

Fig. 1· Type 2408 Excess Pressure Valve

Edition June 2010

Mounting and

Operating Instructions

EB 2528 EN

Contents Page

1 Design and principle of operation . . . . . . . . . . . . . . . . . . . . . . 4

1.1 Process medium, application range, versions. . . . . . . . . . . . . . . . . 4

2 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

2.1 Mounting position. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

2.2 Strainer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

2.3 Shut-off valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

2.4 Pressure gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

2.5 Control line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

3 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

3.1 Start-up. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

3.2 Adjusting the set point. . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

3.3 Decommissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

4 Maintenance and troubleshooting . . . . . . . . . . . . . . . . . . . . . . 8

4.1 Pressure fluctuations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

5 Nameplate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

6 Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

7 Technical data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

8 Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

2EB 2528 EN

Contents

CAUTION!

Indicates a hazardous situation which, if not

avoided, could result in minor or moderate

injury.

NOTICE

Indicates a risk of property damage.

Note! Indicates supplementary explanations,

information and tips.

Definitions of the signal words used in these instructions

EB 2528 EN 3

Safety instructions

General safety instructions

Observe the following instructions on installation, start-up and operation of the regulator for

your own safety:

The regulator is to be mounted, started up or serviced by fully trained and

qualified personnel only, observing the accepted industry codes and practices.

Make sure employees or third persons are not exposed to any danger.

All safety instructions and warnings in these mounting and operating

instructions, particularly those concerning assembly, start-up and

maintenance, must be observed.

According to these mounting and operating instructions, trained personnel is

referred to as 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 regulator fulfils the requirements of the European Pressure Equipment

Directive 97/23/EC.

For appropriate operation, make sure that the regulator is only used in areas

where the operating pressure and temperatures do not exceed the operating

values specified in the order that the valve sizing data are based on.

The manufacturer does not assume any responsibility for damage caused by

external forces or any other external influence!

Any hazards that could be caused in the regulator by the process medium, the

operating pressure or by moving parts are to be prevented by means of the

appropriate measures.

Proper shipping and storage are assumed.

Note! Non-electric valve versions whose bodies are not lined with an insulating material coat-

ing do not have their own potential ignition source according to the risk assessment stipulated in

EN 13463-1:2001, section 5.2, even in the rare incident of an operating fault. Therefore, such

valve versions do not fall within the scope of Directive 94/9/EC.

1 Design and principle of opera-

tion

See also Fig. 2, page 5.

NOTICE

Install a strainer (e.g. SAMSON Type 2 NI)

upstream of the regulator (refer to sec-

tion 2.2).

Make sure the regulator is mounted free of

stress. If necessary, support the piping near

the connecting flanges. Never attach supports

directly to the valve or actuator.

2.1 Mounting position

Mounting position (preferable)

– Install the regulator in a

horizontal pipeline with the

actuator housing and set

point adjuster pointing ver-

tically up,

– The direction of flow must correspond to

the arrow on the body,

– Install the control line with a downward

slope of approx. 10 % towards the tapping

point to allow condensed liquid to flow

back into the tank or pipeline.

Other mounting positions

–Install the regulator in a

vertical pipeline with the

actuator housing and set

point adjuster pointing to

the side.

Note! Higher system deviations may occur in

this mounting position.

–Make sure the direction of flow matches the

arrow on the body (from bottom to top).

4EB 2528 EN

Design and principle of operation

EB 2528 EN 5

Installation

1 Valve body

2 Seat

3 Plug

4 Plug stem

5 Diaphragm plate with operating diaphragm

6 Actuator housing

7 Set point spring

8 Set point adjuster

9 Control line connection (G ¼ tapped connection for upstream pressure p1)

10 Cap

Fig. 2 · Design and principle of operation, Type 2408 Excess Pressure Valve

2.2 Strainer

Install a strainer upstream of the regulator

(Fig. 3). Install the strainer with the direction

of flow matching the arrow on the body.

Make sure the filter element is vertically sus-

pended. Remember to leave enough space to

remove it.

2.3 Shut-off valve

Install a hand-operated shut-off valve both

upstream of the strainer and downstream of

the regulator (Fig. 3) to be able to shut down

the plant for cleaning and maintenance, and

when the plant is not used for longer periods

of time.

2.4 Pressure gauge

To monitor the pressures in the plant, install a

pressure gauge both upstream and down-

stream of the regulator (Fig. 3).

2.5 Control line

G ¼ tapped connection (9) at the actuator

housing. Install a control line with at least

6 mm inside diameter on site, preferably an

8x1mmpipe made of steel or stainless steel.

Always attach the control line connection for

pressure tapping directly to the tank or vessel

as the medium is fully expanded and free of

turbulence at this point.

6EB 2528 EN

Installation

Fig. 3 · Sample installation

min.

2 x DN

min. 5 x DN

241

p1p2

min.

3 x DN

Type 2408

≈10 % slope towards

pressure tapping

point

≈10 % slope towards

pressure tapping

point

1 Shut-off valve

2 Pressure gauge (upstream pressure)

3 Strainer

4 Pressure gauge (downstream pressure)

When tapping the pressure at a straight pipe-

line section, observe a minimum distance of

at least twice the nominal valve size to the

regulator.

Connect the control lines to the side or top of

the main horizontal pipeline. If possible, in-

stall the tapping connection in a pipe expan-

sion.

Install other fittings that may cause flow turbu-

lence (e.g. shut-off valves, restrictions, bows,

bends or branches) at an appropriate dis-

tance to the control line connection (at least

three times the nominal valve size).

Note! If the gas to be controlled contains

moisture, condensate may form in the control

line, which can damage the regulator. To al-

low the gas to flow back into the tank or pipe-

line, install the control line with a downward

slope of approx. 10 % towards the pressure

tapping point.

3 Operation

3.1 Start-up

See also Fig. 2, page 5.

NOTICE

Do not start up the regulator before all com-

ponents have been installed.

Make sure the control line is free of dirt or

other contaminations that may impair the

proper medium flow.

Connect the line properly.

We recommend to open shut-off valves

slowly from the downstream side. Avoid

pressure surges.

NOTICE

The max. permissible pressure at the operat-

ing diaphragm must not exceed 0.5 bar with

A = 1200 cm², 1 bar with A = 640 cm²,

2 bar with A = 320 cm² and 4 bar with A =

160 cm².

Make sure this pressure is not exceeded, par-

ticularly when pressure-testing the plant with

the regulator installed or when starting up the

plant.

3.2 Adjusting the set point

Adjust the desired set point by tensioning the

set point springs using the set point adjuster

(SW 27/¾" adjustment screw).

4Remove the cap (10).

4Turn the adjustment screw using a socket

wrench with width across flats SW 27.

4Turn the adjuster clockwise Pto increase

the set point and counterclockwise Qto

reduce it.

4Remount the cap.

EB 2528 EN 7

Operation

Fig. 4 · Set point adjustment; view from top

Adjustment screw

SW 27 (¾")

Check the adjusted set point on the pressure

gauge installed upstream of the regulator

(Fig. 3).

3.3 Decommissioning

We recommend to close the upstream shut-off

valve before closing the shut-off valve in-

stalled downstream of the regulator.

4 Maintenance and trouble-

shooting

The pressure regulator is maintenance free.

Nevertheless, it is subject to natural wear,

particularly at the seat, plug and operating

diaphragm.

Depending on the operating conditions, the

regulator needs to be checked at regular in-

tervals to detect and remove possible mal-

functions.

CAUTION!

For installation and maintenance work on the

regulator, make sure the relevant plant sec-

tion has been depressurized and, depending

on the process medium, drained as well. We

recommend to remove the regulator from the

pipeline.

If necessary, allow the regulator to cool down

to reach ambient temperature before starting

any work on it.

Disconnect or shut off the control line to avoid

any hazards that could be caused by moving

regulator parts.

As valves are not free of cavities, remember

that residual process medium might still be

contained in the valve.

4.1 Pressure fluctuations

NOTICE

Pressure fluctuations (oscillation) may dam-

age the regulator and plant. As a result, pre-

vent them from occurring or remove their

cause immediately.

To stop oscillation from occurring, the follow-

ing actions may be helpful:

4Check the pressure tapping point at the

control line (refer to section 2.5); if neces-

sary, move the tapping point.

4Screw a SAMSON restriction into the

sleeve for the tapped connection (9): or-

der no. 1991-7114 for 1200 and

640 cm², order no. 1991-7113 for 320

and 160 cm².

4Check the regulator's sizing data. If nec-

essary, change the KVS coefficient, seat di-

ameter or diaphragm area.

Contact SAMSON (refer to section 6) if the

problems persist.

8EB 2528 EN

Maintenance and troubleshooting

5 Nameplate

6 Service

If malfunctions or defects occur, contact the

SAMSON After-sales Service for support.

The addresses of SAMSON AG, its subsidiar-

ies, representatives and service facilities

worldwide can be found on the Internet at

www.samson.de, in a SAMSON product cat-

alog or on the back of these mounting and

operating instructions.

Include the following details when making in-

quiries:

4Type and nominal size of the regulator

4Configuration ID (Var-ID)

4Upstream and downstream pressures

4Temperature and process medium

4Min. und max. flow rates

4Has a strainer been installed?

4Installation drawing indicating the exact

location of the regulator and all addition-

ally mounted units (shut-off valves, pres-

sure gauges etc.)

EB 2528 EN 9

Nameplate

Fig. 5 · Nameplate

Legend

1 Configuration ID (VAR-ID)

2 Manufacturing data

3 Type designation (2408)

4 Max. perm. differential pressure

in bar

5 Max. perm. temperature in °C

6 Nominal size DN or connection

thread G

VS coefficient

8 Set point range in bar

9 Nominal pressure PN

9SAMSON

3 5

7 Technical data

10 EB 2528 EN

Technical data

Table 1 · Technical data

Connection · Nominal size G ½, G ¾ and G 1

Stainless steel DN 15 and DN 25

Spheroidal graphite iron

Nominal pressure PN 25

Control line connection for

8 x 1 mm pipe G ¼

KVS coefficients 0.25 · 1.0 · 2.5 · 3.21) · 5.01)

Max. perm. differential pressure Δp 6 bar

Max. perm. pressure at the actuator

Actuator area A = 1200 cm²

Actuator area A = 640 cm²

Actuator area A = 320 cm²

Actuator area A = 160 cm²

0.5 bar

1 bar

2 bar

4 bar

Permissible temperature range of the

medium –20 to +60 °C

Leakage class acc. to DIN EN 60534-4 Soft seal, at least class IV

Set point ranges 5 to 15 mbar · 10 to 30 mbar · 25 to 60 mbar · 50 to 200 mbar

100 to 1000 mbar

1) Only in conjunction with 100 to 1000 mbar set point range

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