Samson 41-23 Series Service manual

Mounting and

Operating Instructions

EB 2512 EN

Translation of original instructions

Edition March 2016

Type 41-23 Pressure Reducing Valve

Self-operated Pressure Regulators

Type41-23 Universal Pressure Reducing Valve

Denition of signal words

DANGER!

Hazardous situations which, if not

avoided, will result in death or seri-

ous 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 2512 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.

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

Department (aftersalesser[email protected]).

Contents

EB 2512 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 ..................................................................5

4 Installation ....................................................................................................6

4.1 Assembly ......................................................................................................6

4.2 Mounting position..........................................................................................8

4.3 Control line, compensation chamber and needle valve......................................9

4.4 Strainer(lter)..............................................................................................10

4.5 Shut-off valve...............................................................................................10

4.6 Pressure gauge ............................................................................................10

5 Operation ...................................................................................................11

5.1 Start-up.......................................................................................................11

5.2 Adjusting the set point..................................................................................11

5.3 Decommissioning.........................................................................................12

6 Cleaning and maintenance .......................................................................... 13

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

7 Customer inquiries ......................................................................................15

8 Dimensions .................................................................................................15

9 Nameplate ..................................................................................................17

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

4 EB 2512 EN

General safety instructions

1 General safety instructions

−The regulator is to 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.

EB 2512 EN 5

Process medium and scope of application

2 Process medium and scope of application

Pressure regulators for set points from 0.05 to 28bar · Valve nominal sizes DN15 to 100

Nominal pressure PN16 to 40 · Suitable for liquids, gases and vapors up to 350°C

The valve closes when the downstream pressure rises.

NOTICE

The Type41-23 Pressure Reducing Valve is not a safety valve. If necessary, 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 regulator against

adverseinuences,suchasdirt,moistureorfrost,duringstorageandtransportation.

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

on the valve body.

NOTICE

Do not attach any lifting equipment, slings or supports to mounting parts, such as the

adjusting screw or control line.

3 Design and principle of operation

See Fig.1 on page7.

TheType41-23PressureReducingValveconsistsofaType2412ClosingValveanda

Type2413Actuator.Thevalveandactuatoraredeliveredseparatelyandmustbeassembled

accordingtotheinstructionsinsection4.1.

The pressure reducing valve is used to maintain the pressure downstream of the valve to an

adjusted set point.

Theprocessmediumowsthroughthevalvebetweenseat(2)andplug(3)inthedirectionin-

dicatedbythearrowonthebody.Thepositionofthevalveplugdeterminestheowrate

and the pressure ratio across the valve. The plug stem is sealed by a frictionless bellows

(5.1).Thedownstreampressurep2istransmittedthroughthecompensationchamber(18)

andcontrolline(17)totheoperatingdiaphragm(12)whereitisconvertedintoapositioning

force. For actuator versions with a bellows, the pressure is transmitted to the operating bel-

6 EB 2512 EN

Installation

lows(12.1).Thepositioningforceisusedto

move the valve plug according to the force of

thepositioningsprings(7).Thespringforce

isadjustableatthesetpointadjuster(6).

Valves with KVS4andhigherfeatureabal-

ancingbellows(4).Theupstreampressure

acts on the outside of the bellows and the

downstream pressure on the inside of the

bellows. As a result, the forces produced by

the upstream and downstream pressures act-

ing on the plug are balanced.

Depending on the valve and actuator used,

the regulator can be upgraded to create a

pressurereducingvalveforlowowrates,a

steam pressure reducing valve or a pressure

reducing valve with increased safety.

4 Installation

4.1 Assembly

See Fig.1 on page7.

Valve and actuator can be assembled before

or after the valve has been installed in the

pipeline.

Pushthediaphragmactuator(10)withactu-

atorstem(11)throughtheholeinthecross-

beam(8)ontothespigotsofthebellows

(5.1).Alignitandfastenwithnuts(width

acrossats16,9)ontothevalveange(ap-

prox.25Nm).

For metal bellows actuators in DN15 to 50,

removethecrossbeam(8)fromthevalve.

Pushtheactuatorstem(11)ontothespigots

ofthebellows(5.1).Alignthepillars(8.1)

andfastenwithnuts(widthacrossats24,

8.2)totheactuator(max.60Nm).

For metal bellows actuators in DN65 to

100,removethecrossbeam(8)fromthe

valveandunscrewthepillars(8.1).Screw

thepillarsintothethreadedholes(8.3)ofthe

actuatorangeasfarastheywillgo.Push

theactuatorwithactuatorstem(11)ontothe

spigotsofthebellows(5.1).Fastenthepillars

withnuts(widthacrossats24,8.2)ontothe

valveange(max.60Nm).

1 Valve body

2 Seat

3 Plug

4 Balancing bellows

5 Plug stem

5.1 Bellows

6 Set point adjuster

7 Positioning springs

8 Crossbeam

8.1 Pillar

8.2 Nuts for pillar

8.3 Threaded holes

9 Fastening nuts

10 Diaphragm actuator

11 Actuator stem

12 Operating diaphragm

12.1 Operating bellows

13 Diaphragm plate

14 Nut

15 Nuts and bolts

16 Control line connection G ¼ (for steam including

screwjointwithrestriction)

17 Control line installed on site (control line kit avail-

able for tapping the pressure directly at the valve

body,seeT2595)

18 Compensation chamber

19 Filler plug

20 Anti-rotation clip

EB 2512 EN 7

Installation

5.1

13 14

12.1

8.2 8.2

8.1

8.2

(25 Nm)

(40 Nm)

8.3

Fig.1: Functional diagram

Table1: Assignment of compensation chamber (18) to

regulator

Actuator area A in

cm²

Item number∙Compensation chamber

DN15 to 50 DN65 to 250

640 1190-8789 1190-8790

320 1190-8788 1190-8789

160/80/40 1190-8788

DN65to100

Type2413 Actuator with metal

bellowsfor2to6bar,5to10bar,

20to28barand10to22bar

DN15to50

Type 2412 Valve

Type2413

Diaphragm Actuator

Item 14: Apply Loctite 272 sealant

(SAMSONorderno.8121-4000)to

the bottom section of thread on the

actuator stem during assembly.

NOTICE: this does not apply to version

for oxygen service or the FDA-

compliant version.

8 EB 2512 EN

Installation

4.2 Mounting position

NOTICE

Protect the regulator from icing up

when controlling media that can

freeze. Remove the regulator from

the pipeline when the plant is shut

down if the regulator is not installed

areas free from frost.

Flush the pipeline thoroughly before install-

ing the regulator to ensure that any sealing

parts, weld spatter and other impurities car-

ried along by the process medium do not im-

pair the proper functioning of the valve,

above all the tight shut-off.

NOTICE

Install a strainer (e.g. SAMSON

Type2) upstream of the regulator.

Install the pressure reducing valve in hori-

zontal pipelines. On installing the valve,

makesurethedirectionofowcorresponds

with the arrow on the body. For media with

a tendency to condensate, 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 valve run vertically upwards, an auto-

matic water drainage (e.g. SAMSON

Type13ESteamTrap)isrequired.Choosea

place of installation that allows you to freely

access the regulator even after the entire

plant has been completed. The regulator

must be installed free of stress. If necessary,

supportthepipeneartheconnectingang-

es.

Standard mounting position

for gases, liquids and steam

Not for millibar pressure

regulator

(A=1200cm²)

Alternative mounting position

for gases and liquids at medium

temperatureupto80°C

Prescribed mounting position

for millibar pressure regulators

(A=1200cm²)

Not for steam

Not permissible! 1)

1) On request: Permissible for

regulatorswithxedplugstemguide

plus with medium temperature up to

80°C.Notforsteam.

Fig.2: Mounting position

NOTICE

Do not attach supports directly to the

valve or actuator.

If a bypass line is to be used, it must be con-

nected downstream of the pressure tapping

point. Install a shut-off valve in the bypass

line.

Note:

Do not install any instruments (e.g.

temperature regulators or shut-off

valves) that restrict the cross-section

of the pipe between the pressure tap-

ping point and the valve.



EB 2512 EN 9

Installation

4.3 Control line, compensation

chamber and needle valve

Control line · A control line must be provid-

ed at the site of installation, e.g. a

“ pipe

forsteamoran8x1or6x1mmpipefor

air/water.

Connect the control line to the downstream

line (p2)atleastonemeterawayfromthe

valveoutlet(Fig.3.1).Ifamanifoldislocat-

ed downstream of the pressure reducing

valve(Fig.3.2),connectthevalvetothe

manifold, even if it is several meters away. If

the downstream line behind the valve is ex-

tended by a conical expansion piece, con-

nect the control line in the expanded section

of the line. Weld the control line at the side

in the middle of the pipe, inclining at a ratio

of approximately 1:10 up to the compensa-

tion chamber.

Control line kit · A control line kit for tap-

ping pressure directly at the valve body is

available as an accessories part from

SAMSON.

Compensation chamber∙SeeTable1on

page7.Acompensationchamberisre-

quiredforliquidsabove150°Caswellas

for steam.

Fig.3: Examples of installation with steam 3.4 Connection above the middle of the ange

NOTICE

Always install the millibar pressure

regulator upright with the actuator

on top.

3.3 Control line connection below the

middle of the ange

3.2 Control line connection in manifold

3.1 Control line connection Min. pipe

diameter ½“

Additional

condensate

head

12 53 467

1235

1 Shut-off valve

2 Upstream pressure gauge

3 Strainer

4 Compensation chamber

5 Pressure reducing valve

6 Downstream pressure gauge

7 Shut-off valve

8 Steam trap

10 EB 2512 EN

Installation

The mounting position of the compensation

chamber is indicated by an adhesive label

on the chamber itself as well as by an arrow

and the word "top" stamped on the top of

the chamber.

Thismountingpositionmustbeadheredto;

otherwise the safe functioning of the pressure

reducing valve cannot be guaranteed.

Weld the line coming from the pressure tap-

ping point to the

“ pipe socket on the

chamber. Install the compensation chamber

at the highest point of the pipeline. Conse-

quently, the control line between compensa-

tion chamber and actuator must also be in-

stalled 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outletange,arrange

the compensation chamber at the same level

astheoutletange(Fig.3.3).Inthiscase,

use a pipe which is at least ½“ in size for the

control line from the tapping point to the

compensation chamber.

If the control line is connected above the

middleofthevalveoutletange,installthe

compensation chamber at the same level as

the downstream pressure tapping point

(Fig.3.4).Theadditionalpressureofthe

condensate head must be compensated for

by adjusting the set point to a higher value.

Needle valve · If the regulator tends to hunt,

we recommend installing a needle valve at

thecontrollineconnection(16)inadditionto

the standard SAMSON screw joint with re-

striction.

4.4 Strainer (lter)

Install the strainer (e.g. SAMSON

Type2N/2NI)upstreamofthepressurere-

ducingvalve(seeFig.3).

−Selectastrainer(meshsize)suitablefor

the process medium.

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

the arrow on the body.

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

hang downwards or sideways for appli-

cations with steam.

−Remember to leave enough space to re-

movethelterelement.

4.5 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.

4.6 Pressure gauges

Install a pressure gauge both upstream and

downstream of the regulator to monitor the

pressures prevailing in the plant. Install the

pressure gauge on the downstream side be-

hind the downstream pressure tapping point

(not between the tapping point and the

valve).

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