Samson 2357-11 Service manual

Mounting and

Operating Instructions

EB 2560 EN

Edition August 2014

Type2357-11 Pressure Build-up Regulator/Type 2357-21 Excess Pressure Valve

Self-operated Pressure Regulators

Type 2357-11 Pressure Build-up Regulator

Type 2357-21 Excess Pressure 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 se-

rious injury

NOTICE

Property damage message or mal-

function

Note:

Additional information

Tip:

Recommended action



2 EB 2560 EN

Contents

EB 2560 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 Mounting position..........................................................................................8

4.2 Shut-off valve.................................................................................................8

5 Operation.....................................................................................................8

5.1 Start-up.........................................................................................................8

5.2 Set point adjustment.......................................................................................8

5.2.1 Changing the set point range..........................................................................9

5.3 Decommissioning.........................................................................................10

6 Maintenance ...............................................................................................10

6.1 Exchanging the seat and plug.......................................................................10

6.2 Exchanging the non-return unit .....................................................................11

7 Customer service.........................................................................................12

8 Nameplate..................................................................................................12

9 Dimensions and weights..............................................................................13

10 Technical data.............................................................................................14

4 EB 2560 EN

General safety instructions

1 General safety instructions

−The regulators are 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 person-

nel 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. The declaration of conformity issued for a regula-

tor bearing the CE marking includes information on the applied conformity

assessment procedure. The declaration of conformity is available 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 pressure regulator by the process

medium, operating pressure or by moving parts are to be prevented by tak-

ing appropriate precautions.

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

sumed.

EB 2560 EN 5

Process medium and scope of application

2 Process medium and scope of application

Pressure regulators for cryogenic gases and liquids as well as other liquids, gases and va-

pors. Operating pressures up to 63bar, with set points from 1 to 40bar. Temperature range

from –200 to +200°C. Oxygen clean according to international standards and guidelines.

The regulators are designed to keep the pressure constant to the adjusted set point, especial-

ly in cryogenic plants.

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 regulators must be carefully handled, transported and stored. Protect the regulators

against adverse inuences, such as dust, dirt or moisture before they are installed.

In the delivered state, the pressure regulators are packed to be free of oil and grease for oxy-

gen service. To avoid contamination, do not open the packaging until immediately before in-

stallation.

6 EB 2560 EN

Design and principle of operation

3 Design and principle of op-

eration

See Fig. 1 on page7.

Ports A and B are marked on the valve body.

Type 2357-11 Pressure Build-up Regulator

Functioning as a Type 2357-11 Pressure

Build-up Regulator (Fig. 1) with direction of

ow from port B to port A, the pressure up-

stream of the valve (port B) is transmitted to

the operating diaphragm. The valve closes

when the upstream pressure increases and

opens when the upstream pressure decreas-

es.

The pressure build-up regulator operates

as a safety valve and relieves the pressure

chamber of pressure when the pressure ex-

ceeds the set point by 5bar. After overcom-

ing the force of the top plug spring (16), the

valve opens to equalize the pressures.

The valve is open when no pressure is ap-

plied. The pressure upstream of the valve

(port B) is transmitted to the operating dia-

phragm (3). The positioning force produced

moves the valve plug (2) depending on the

spring force adjustable at the set point ad-

juster (10). The valve closes when the pres-

sure upstream of the valve (port B) increases.

Type 2357-11 Pressure Reducing Valve

The process medium ows from port A to

port B when the Type2357-11 Pressure Reg-

ulator is used as a pressure reducing valve.

The valve is open when no pressure is ap-

plied. The pressure downstream of the valve

(port B) is transmitted to the operating dia-

phragm (3). The positioning force produced

moves the valve plug (2.1) depending on the

spring force adjustable at the set point ad-

juster (10). The valve closes when the pres-

sure downstream of the valve (port B) rises.

Type 2357-21 Excess Pressure Valve

The medium ows through the Type 2357-21

Excess Pressure Valve (Fig. 3) from port B to

port A. The valve is closed when no pressure

is applied. The pressure at port B is trans-

mitted internally to the operating diaphragm

(3). The positioning force produced opposes

the adjustable spring force. The valve opens

when the pressure increases until the set

point is reached. The integrated non-return

unit prevents the medium from owing back.

EC type examination

An EC type examination according to the

Pressure Equipment Directive 97/23/EC,

Module B has been performed on the regu-

lators.

EB 2560 EN 7

Design and principle of operation

Fig. 1: Functional diagram

Direction of ow

Pressure build-up regulator

Pressure reducing valve

1 Valve body

2.1 Plug

3 Operating diaphragm

4.1 Gasket (bottom section of the body)

5 Diaphragm plate

6 Ball

7 Spring plate

8 Set point springs

9 Spring housing (bottom section of the

body)

10 Set point adjuster (hexagon socket,

5mm)

11 Lock nut (17mm)

12 Integrated non-return unit

14 Body screws

15 Seat

16 Plug spring

Type2357-11

Type2357-21

2.1

4.1

8 EB 2560 EN

Installation

4 Installation

In the delivered state, the regulators are

packed to be free of oil and grease for oxy-

gen service.

WARNING!

Use of oil and grease in oxygen at-

mospheres!

Risk of explosion!

Make sure that the regulator is abso-

lutely clean and free of oil and grease

on installing it.

Flush and clean the pipeline thoroughly be-

fore installing the regulator.

−Make sure the regulator is installed free

of stress.

−Install a strainer upstream of the regu-

lator.

Otherwise, impurities in the pipeline

may impair the proper functioning of the

valve, above all the tight shut-off.

4.1 Mounting position

Install the pressure regulator with

the actuator housing suspended

downward in horizontal pipelines.

Observe the ow direction.

Type 2357-11 Pressure Build-up Regulator

with safety function

−Direction of ow from port Bto port A

Type 2357-11 Pressure Reducing Valve

−Direction of ow from port Ato port B

Type 2357-21 Excess Pressure Valve with

with non-return unit

−Direction of ow from port Bto port A

The ports are marked.

Required spare parts and accessories are

listed in Data Sheet uT2570EN.

4.2 Shut-off valve

We recommend installing a hand-operat-

ed shut-off valve both upstream and down-

stream of the regulator. This allows the plant

to be shut down for cleaning and mainte-

nance, and when the plant is not used for

longer periods of time.

Install a pressure gauge at a suitable point to

monitor the pressures prevailing in the plant.

5 Operation

See Fig. 1 on page7.

5.1 Start-up

First start up the regulator after mounting all

parts.

5.2 Set point adjustment

Every pressure regulator is delivered with the

set point listed in Table 1 already adjusted.

Turn the set point adjuster (10) using Al-

len key (size 5mm) to change the default set

point.

Provided a pressure gauge has been in-

stalled at a suitable point in the plant, the

required set point can be directly adjusted

EB 2560 EN 9

Operation

while monitoring the pressure reading at the

gauge.

When a pressure gauge is not installed, ad-

just the set point using the adjustment dia-

gram Fig. 2.

To increase the set point, turn the set point

adjuster into the body () and out of the

body () to reduce it.

NOTICE!

Set point adjuster screwed too tight!

The regulator is blocked and the me-

dium ow through it is restricted. Pres-

sure regulation is no longer possible!

Only screw the set point adjuster up

to the point where the spring tension

can still be felt!

How to proceed:

1. Loosen the lock nut (11, size 17mm) to

allow the set point adjuster to move free-

ly.

2. Determine the difference between the

xed set point (Table 1) and the required

set point. Turn the set point adjuster (10)

the required amount of turns as specied

in Fig. 2 on page10.

Based on the default setting, any subsequent

change to the set point can be also be made

by determining the required number of turns

using the specications listed in Table 1.

3. Lock the setting with the lock nut (11).

5.2.1 Changing the set point

range

The default set point ranges can be adapt-

ed to your specic requirements. Contact

SAMSON (see section7) for further details.

Table 1: Set point adjustment (default)

Set point range 1 to 8bar 5 to 25bar 8 to 40bar

Set point adjusted at the factory

(approx.)

2357-11 3bar 12bar 25bar

2357-21 4bar 13bar 26bar

Set point change per turn 1bar 2.5bar 3.5bar

10 EB 2560 EN

Maintenance

012345678910 11 12 13 14

1...8 bar

5...25 bar

8...40 bar

Fig. 2: Adjustment diagram

5.3 Decommissioning

Close rst the shut-off valve on the upstream

side of the valve and then on the down-

stream side of the valve.

Turns of the set point adjuster

: to increase the set point

: to reduce the set point

Set point

[bar] 6 Maintenance

The regulators do not require any mainte-

nance. Nevertheless, they are subject to nat-

ural wear, particularly at the seat, plug and

operating diaphragm.

Depending on the operating conditions,

check the regulator at regular intervals to

avoid possible malfunctions.

WARNING!

Process medium can escape uncon-

trolled on dismantling the regulator.

Risk of cold burns!

Allow the regulator to defrost before

depressurizing and draining it and re-

move it from the pipeline.

If faults or malfunctions cannot be remedied,

contact SAMSON (see section7).

6.1 Exchanging the seat and

plug

See Fig. 1 on page7.

1. Loosen the lock nut (11) and turn the set

point adjuster (10) counterclockwise to

fully relieve the internal set point springs

(8).

2. Unscrew the body screws (14) using an

open-end wrench (size 19mm). Lift off

the valve body (1).

3. Unscrew the seat (15) using a seat

wrench (size 30mm socket). Remove the

plug (2.1).

Set point ranges

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