Samson 2422 series Service manual

Mounting and

Operating Instructions

EB 2549 EN

Edition January 2016

Type2422/2425 Excess Pressure Valve

Self-operated Pressure Regulators

Type2422/2425 Excess Pressure Valve

Denition of signal words

DANGER!

Hazardous situations which, if not

avoided, will result in death or serious

injury

WARNING!

Hazardous situations which, if not

avoided, could result in death or seri-

ous injury

NOTICE

Property damage message or mal-

function

Note:

Additional information

Tip:

Recommended action



2 EB 2549 EN

Contents

EB 2549 EN 3

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 ....................................................................................................8

4.1 Assembly ......................................................................................................8

4.2 Mounting position ..........................................................................................9

4.3 Notes on installation ......................................................................................9

4.4 Control line, condensation chamber and needle valve .....................................10

4.5 Strainer .......................................................................................................11

4.6 Shut-off valve ...............................................................................................11

4.7 Pressure gauge ............................................................................................11

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

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

5.2 Adjusting the set point ..................................................................................12

5.3 Decommissioning .........................................................................................13

6 Maintenance and troubleshooting ................................................................13

6.1 Replacing the operating diaphragm ..............................................................13

7 Nameplate ..................................................................................................14

8 Customer service .........................................................................................15

9 Dimensions .................................................................................................16

10 Technical data .............................................................................................18

Contents Page

4 EB 2549 EN

General safety instructions

1 General safety instructions

−The regulator 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 persons 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 regulators comply with the requirements of the European Pressure Equip-

ment Directive 97/23/EC. Devices with a CE marking have a declaration of

conformity, which includes information about the applied conformity assess-

ment procedure. This 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 regulator by the process medium,

operating pressure or by moving parts are to be prevented by taking appro-

priate precautions.

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

sumed.

Note:

Non-electric actuators and control valve versions do not have their own

potential ignition source according to the ignition risk assessment stipulat-

ed in EN13463-1: 2009, section 5.2, even in the rare incident of an op-

erating fault. Therefore, they do not fall within the scope of Directive

94/9/EC. For connection to the equipotential bonding system, observe the

requirements specied in section 6.3 of EN60079-14 (VDE0165 Part 1).



EB 2549 EN 5

Process medium and scope of application

2 Process medium and scope of application

Pressure regulator for liquids, gases and vapors up to 350°C

For controlling the upstream pressure p1 to the adjusted set point. The valve opens when the

upstream pressure rises. The upstream pressure is transmitted to the actuator over a control line

that must be installed on site.

The pressure regulators are not shut-off devices guaranteeing tight shut-off. When closed, these

regulators can have a leakage rate of ≤0.05% of the KVS coefcient.

Overpressure protection must be installed in the plant.

WARNING!

Risk of injury and property damage due to high pressure in the plant.

A suitable overpressure protection must be installed on site in the plant section.

2.1 Transportation and storage

The regulator must be carefully handled, transported and stored. Protect the excess pressure

valve against adverse inuences, such as dirt, moisture or frost, during storage and transpor-

tation.

When regulators are too heavy to be lifted by hand, fasten the lifting sling at a suitable place

on the valve body.

WARNING!

Incorrectly attached lifting slings or supports.

Risk of injury and property damage due to valve falling.

Securely fasten slings or supports to the valve body and secure against slipping.

6 EB 2549 EN

Design and principle of operation

3 Design and principle of op-

eration

See Fig.1 and Fig.2.

The Type2422/2425 Excess Pressure Valve

consists of the Type 2422 Valve and the

Type2425 Actuator. The Type2422 Valve is

available either balanced by a bellows or a

diaphragm.

The excess pressure valve is used to maintain

the pressure upstream of the valve to an ad-

justed set point. The valve opens when the up-

stream pressure rises.

The medium ows through the valve in the di-

rection indicated by the arrow. The position of

the plug (3) determines the ow rate across

the area released between plug and valve

seat (2). The plug stem (4) with the plug is

connected to the top diaphragm stem (8) of

the actuator (10).

The upstream pressure p

is regulated by the

positioning springs (11) and the set point ad-

juster (13). When relieved of pressure, the

valve is closed by the force of the set point

springs.

The upstream pressure p1 to be controlled is

tapped upstream of the valve and transmitted

over the control line to the operating dia-

phragm (9) where it is converted into a posi-

tioning force. This force is used to move the

valve plug according to the force of the posi-

tioning springs. When the force resulting from

the upstream pressure p1 rises above the ad-

justed set point, the valve opens proportional-

ly to the change in pressure.

The principle of operation of the

Type2422/2425 Excess Pressure Valve bal-

anced by a bellows or diaphragm only differs

concerning the pressure balancing. The valves

balanced by a diaphragm have a balancing

diaphragm (5.1) instead of a bellows (5). In

both cases, the forces created by the upstream

and downstream pressures that act on the

valve plug are balanced out.

The valves can be supplied with ow divider

StI or StIII. The valve seat must be replaced

on retrotting the ow divider.

The control of vapors and liquids above

150 °C is only possible with a Type 2422

Valve balanced by a bellows. In this case,

condensation chamber (20) is already in-

stalled in the control line1). The needle valve

(18) in the control line is open and lead-

sealed.

Before start-up, ll the condensation chamber

with the process medium at the lling opening

(21) until it overows.

1) Only in combination with a control line kit.

Otherwise, the condensation chamber must be

ordered separately (see uT2595).

EB 2549 EN 7

Design and principle of operation

Fig.1: Functional diagram of Type2422/2425 balanced by a bellows

Type 2422 Valve,

balanced by a

bellows

Type2425 Actuator

20 21

6.1

6.2

8.1

1 Type 2422 Valve

2 Seat (exchangeable)

3 Plug

4 Plug stem

4.1 Actuator stem

5 Balancing bellows

6 Bellows housing

6.1 Vent screw (640cm², bellows

housing)

6.2 Vent screw (connection to

actuator)

7 Coupling nut

8Top diaphragm stem

8.1 Nut

9Operating diaphragm

10 Type2424 Actuator

11 Positioning springs

13 Set point adjuster

14 Bottom diaphragm stem

15 Nuts and bolts

16 Nut

17 Diaphragm plate

18 Control line connection (for

steam including screw joint with

restriction and needle valve)

19 Control line

20 Condensation chamber for tem-

peratures above 150°C and for

steam

21 Filling opening with plug

p1Upstream pressure

p2Downstream pressure

p1p2

8 EB 2549 EN

Installation

4 Installation

See Fig.1 and Fig.2.

4.1 Assembly

Valve and actuator can be assembled before

or after the valve has been installed in the

pipeline.

Relieve the positioning springs of tension

by turning the set point adjuster (13).

ÎPlace the actuator on the bellows housing

and carefully screw it in as far as it will

go. Make sure the control line connection

points toward the upstream pressure side.

Hold the actuator and fasten it to the bel-

lows housing using the coupling nut (7).

Fig.2: Functional diagram of Type2422/2425 balanced by a diaphragm

5.1 Balancing diaphragm

p1Upstream pressure

p2Downstream pressure

Type 2422 Valve,

balanced by a

diaphragm

Type2425 Actuator

5.1

P1P2

EB 2549 EN 9

Installation

4.2 Mounting position

Select the installation location making sure

that the regulator is installed at a distance of

at least six times the nominal 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 espe-

cially in applications with gases, air or steam.

Contact SAMSON to obtain the TV-SK17041

documentation which contains more details on

installation requirements.

4.3 Notes on installation

Install the excess pressure valve in horizontal

pipelines.

−Flush the pipeline thoroughly before in-

stalling the regulator to ensure that no

impurities impair the proper functioning

of the valve, above all the tight shut-off.

−Direction of ow must match the direction

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.

Fig.3: Sample application

3451

1 Shut-off valve

2 Upstream pressure

gauge

3 Strainer (lter)

4 Type2422/2425

Excess Pressure Valve

5 Downstream pressure

gauge

6 Bypass piping

p1Upstream pressure

p2Downstream pressure

10 EB 2549 EN

Installation

Mounting position

Valve balanced by a bellows/diaphragm

−Actuator facing downward

Pressure testing of the plant · The pressure

must not exceed the maximum permissible

pressure of the regulator and plant on testing

the pressure of the plant when the regulator is

already installed. An excessive test pressure

can damage the operating diaphragm in the

actuator.

NOTICE

Uncontrolled excess pressure in the

plant may damage the operating dia-

phragm.

The maximum permissible pressure at

the actuator must not exceed the pres-

sure specied in Table1.

Table1: Max. perm. pressure at actuator

Actuator area Max. perm. pressure

640cm² 1.5bar

320cm² 3bar

To prevent damage to the diaphragm, take

one of following precautions:

−Remove the regulator from the pipeline

or isolate the regulator in the pipeline

and install a bypass (see Fig.3) or

−Detach the control line and seal the

openings with end plugs or

−Install a shut-off valve in the control line.

4.4 Control line, condensation

chamber and needle valve

Control line · A control line must be provided

at the site of installation, e.g. a

“ pipe for

steam or an Ø8x1 or Ø6x1mm copper

pipe for air or water.

Connect the control line to the upstream line

(p1) at least one meter away from the valve in-

let. If a manifold is located upstream of the ex

cess pressure valve, connect the valve to the

manifold, even if it is several meters away. If

the upstream line is extended by a conical ex-

pansion piece, connect the control line in the

expanded section of the line. Weld the control

line at the side in the middle of the pipe, in-

clining at a ratio of approximately 1:10 up to

the condensation chamber.

Weld the line coming from the pressure tap-

ping point to the

“ pipe socket on the cham-

ber. Install the condensation chamber at the

highest point of the pipeline. Consequently,

the control line between condensation cham-

ber and actuator must also be installed with a

downward slope. In this case, use a

“ pipe

with screw ttings.

If the control line connection is located below

the middle of the valve inlet ange, arrange

the condensation chamber at the same level

as the inlet ange. In this case, use a pipe

which is at least ½“ in size for the control line

from the tapping point to the condensation

chamber.

If the control line is connected above the mid-

dle of the valve inlet ange, install the conden-

sation chamber at the same level as the up-

stream pressure tapping point. The additional

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