Samson 42-36 Service manual

Self-operated Regulators

Flow Regulator

Type 42-36

Mounting and

Operating Instructions

EB 3015 EN

Edition December 2008

Type 42-36

Contents Page

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

2 Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

2.1 Mounting position . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

2.2 Control line, equalizing tank and needle valve . . . . . . . . . . . . . . 7

2.3 Strainer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

2.4 Shut-off valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

2.5 Pressure gauge. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

3 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

3.1 Start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

3.2 Set point adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . 9

3.3 Decommissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

4 Maintenance · Troubleshooting . . . . . . . . . . . . . . . . . . . . 14

4.1 Replacing the diaphragm . . . . . . . . . . . . . . . . . . . . . . . 14

5 Customer service . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

6 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

7 Nameplates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

8 Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

2EB 3015 EN

Contents

CAUTION!

CAUTION indicates a hazardous situation

which, if not avoided, may result in injury.

NOTICE

NOTICE indicates a property damage

message.

Note: Supplementary explanations, informa-

tion and tips

Definitions of the signal words used in these instructions

EB 3015 EN 3

Safety instructions

General safety instructions

The regulators must be installed, started up and 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.

The regulator complies with the requirements of the European Pressure

Equipment Directive 97/23/EC. The declaration of conformity issued for a

valve bearing the CE marking includes information on the applied conformity

assessment procedure.

The declaration of conformity can be provided on request.

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

applications where the operating pressure and temperatures do not exceed

the operating values based on the sizing data submitted in the order.

Note that the manufacturer does not assume any responsibility for damage

caused by external forces or any other external factors.

Any hazards which could be caused in the regulator by the process medium or

operating pressure are to be prevented by means of appropriate measures.

Proper shipping and appropriate storage are assumed.

Note: Non-electric valve versions which do not have a valve body lined with an insulating

coating do not have their own potential ignition source according to the ignition risk assessment

stipulated in EN 13463-1: 2002, section 5.2, even in the rare incident of an operating fault.

Therefore, they do not fall within the scope of Directive 94/9/EC.

For connection to the equipotential bonding system, observe the requirements specified in

section 6.3 of EN 60079-14: 2003 (VDE 0165 Part 1).

1 Design and principle of

operation

The flow regulator is designed to maintain the

flow rate in the pipeline at the set point ad-

justed at the restriction.

The regulator consists of a Type 2423 Valve

with a seat, plug and a restriction as well as a

Type 2426 Closing Actuator with an operat-

ing diaphragm.

The valve and actuator are delivered as sepa-

rate units and must be connected with a cou-

pling nut on site.

Type 42-36 DoT

This version allows the additional control or

limitation of the temperature by attaching a

double adapter with a thermostat.

See the Mounting and Operating Instructions:

EB 3019 EN for the double adapter and

EB 2231 EN for Type 2231, Type 2232,

Type 2233, Type 2234 and Type 2235 Control

Thermostat.

The medium flows through the valve in the di-

rection indicated by the arrow. The flow rate

is determined by the free area between the re-

striction (1.1) and the valve plug (3).

The valve plug is unaffected by pressure

changes in the medium since the upstream

and downstream pressures are balanced by

the balancing bellows (5) or the balancing di-

aphragm (5.1) (DN 125 to 250/valve bal-

anced by a diaphragm).

The principle of operation of the regulators

with valves balanced by a bellows or dia-

phragm only differ concerning the pressure

balancing. The valves balanced by a dia-

phragm have a balancing diaphragm (5.1)

instead of a bellows (5). The downstream

pressure p2acts on the inside and the up-

stream pressure p1on the outside of the dia-

phragm or bellows. As a result, the forces act-

ing on the valve plug are balanced out.

The high pressure upstream of the restriction

(1.1) is transmitted through the control line

(18) to the lower diaphragm chamber. The

low pressure downstream of the restriction

(1.1) passes through the hollow plug stem (7)

and the diaphragm stem (6) into the top dia-

phragm chamber of the actuator. The differ-

ential pressure produced at the restriction is

converted into a positioning force at the oper-

ating diaphragm (12) and is used to move the

valve plug according to the force of the differ-

ential pressure springs (14). If the flow rate in-

creases, for example, the differential pressure

at the restriction also increases. The actuator

and plug stems move in the closing direction

and the flow rate is reduced until the flow rate

set point adjusted at the restriction (1.1) is

reached. If the flow rate decreases, the re-

verse takes place.

4EB 3015 EN

Design and principle of operation

EB 3015 EN 5

Design and principle of operation

Fig. 1 · Sectional drawing of regulator with valve balanced by a bellows

1.3

1.1

1.2

1.4

Type 42-36 · Balanced by a bellows

DN 15 to 250

Type 2423 Valve

balanced by a

bellows

Type 2426

Actuator

1 Valve body

1.1 Restriction (set point adjustment)

1.2 Lock nut

1.3 Cap

1.4 Orifice

2 Seat

3 Plug

5 Balancing bellows

6 Diaphragm stem

7 Plug stem

8 Venting (DN 125 and higher)

11 Coupling nut

12 Operating diaphragm

14 Differential pressure

spring(s)

15 Screws

16 Diaphragm plate

17 Nut

18 High-pressure control line

2 Installation

Install the regulator in the low-pressure line

(return flow) or in the high-pressure line (flow)

of the plant. Refer to installation schematics in

Fig. 4.

On selecting the position of installation, make

sure that the regulator can still be easily ac-

cessed after completion of the plant.

NOTICE

The regulator must be installed free of stress. If

necessary, support the piping near the con-

nections. However, do not attach supports to

the valve or actuator.

6EB 3015 EN

Design and principle of operation · Installation

Fig. 2 · Sectional drawing of regulator with valve balanced by a diaphragm

Type 42-36 · Balanced by a diaphragm · DN 125 to 250

1 Valve body

1.1 Restriction

(set point adjustment)

1.2 Lock nut

1.3 Cap

1.4 Orifice

2 Seat

3 Plug

5.1 Balancing diaphragm

6 Diaphragm stem

7 Plug stem

11 Coupling nut

12 Operating diaphragm

14 Differential pressure

spring(s)

15 Screws

16 Diaphragm plate

17 Nut

18 High-pressure control line

Type 2426

Actuator

Type 2423 Valve

balanced by a

diaphragm

Note: Install a strainer (e.g. SAMSON

Type 2 N/2 NI) upstream of the regulator to

prevent sealing particles, welding spatter or

other impurities carried along by the process

medium from impairing the proper function-

ing of the valve, especially tight shut-off.

2.1 Mounting position

See Fig. 3 for permissible mounting positions.

Standard mounting position · Install valve

without actuator in a horizontal pipeline with

the connection for the actuator facing down-

wards. Make sure the medium flows through

the valve in the direction indicated by the ar-

row. Then connect the actuator to the valve

using the coupling nut (11).

NOTICE

Protect the regulator when it is used to control

freezing process media.

On shutting down the plant in areas not free

from frost, depressurize and empty the regu-

lator and remove it from the pipeline.

2.2 Control line, equalizing tank

and needle valve

Control line · After mounting the actuator,

fasten the supplied high-pressure control line

to the regulator as shown in Figs. 1 and 2.

Control line kit · A control line kit for tapping

pressure directly at the valve body is avail-

able as an accessory from SAMSON. Refer to

Data Sheet T 3095 EN.

Equalizing tank · An equalizing tank is re-

quired for liquids above 150 °C and for

steam. For the control line, install the equaliz-

ing tank directly downstream of the pressure

tapping point at the valve. The mounting posi-

tion of the equalizing tank is indicated by an

adhesive label on the tank itself as well as by

an arrow and the word "top" stamped onto

the top of the tank. Adhere to the mounting

position and distances prescribed, otherwise

the safe functioning of the regulator cannot

be guaranteed.

Needle valve · If the regulator tends to hunt,

we recommend installing a SAMSON needle

valve in the control line routed on site at the

actuator connection.

EB 3015 EN 7

Installation

Fig. 3 · Permissible mounting positions

–All versions in DN 15 to 80

and up to max. 80 °C

–Standard mounting position

– all versions –

–Above 80 °C,

steam applications

–Only versions with fixed

plug guide and

up to max. 80 °C

Note: Needle valves, equalizing tanks and

compression-type screw fittings can be sup-

plied as required. These accessories are listed

in the Data Sheet T 3095 EN.

2.3 Strainer

A strainer installed in the flow pipe prevents

foreign matter and dirt particles in the me-

dium from entering the regulator. The

SAMSON product range includes the

Type 2 N/2 NI Strainer (refer to Data Sheet

T 1010 EN).

Install the strainer upstream of the regulator.

Make sure the direction of medium flow cor-

responds with the direction indicated by the

arrow on the strainer. The filter element must

be suspended downwards or be located at

the side for applications with steam. Remem-

ber to leave enough space to remove it.

2.4 Shut-off valve

We recommend installing a hand-operated

shut-off valve (Fig. 4) both upstream of the

strainer and at the outlet of the return flow

pipe to be able to shut down the plant for

8EB 3015 EN

Installation

Fig. 4 · Typical installation of Type 42-36, installed in the flow and return flow pipes

1 Shut-off valve

2 Strainer

3 Flow regulator

4 Equalizing tank (optional)

5 Needle valve

6 Pressure gauge

The minimum required plant pressure drop Δpmin

across the valve is calculated from:

Δpmin =Δprestriction +V

⎛

⎝

⎜

⎞

⎠

⎟

Δp in bar

.in m3/h

KVS in m3/h

Type 42-36 installed in the return flow pipe

(T <150 °C)

61 24

Type 42-36 installed in the flow pipe

(T >150 °C)

cleaning and maintenance, and when the

plant is not used for longer periods of time.

2.5 Pressure gauge

To monitor the pressures in the plant, install a

pressure gauge both upstream and down-

stream of the regulator.

3 Operation

3.1 Start-up

CAUTION!

First start up the regulator after mounting all

the components, e.g. valve, actuator and con-

trol line.

Make sure the control line (and needle valve)

is open and correctly connected before

start-up.

For media temperatures above 150 °C

(steam), fill the equalizing tank with the pro-

cess medium (water) before start-up.

Note: On filling the plant, make sure the re-

striction (1.1) is open by turning the adjust-

ment screw counterclockwise as far as it will

go.

4Open all the valves on the consumer side.

Slowly open the shut-off valves starting on

the return flow pipe first. In case of valves

balanced by a bellows in DN 125 or

larger, vent the bellows housing at the

stopper (8) located at the side of the bel-

lows housing.

Rinsing the plant · After filling the plant, first

completely open the consumers. Open the re-

striction. Rinse out the pipeline at full flow rate

for several minutes. Check the installed

strainer (e.g. by measuring the pressure

drop) afterwards. Clean the strainer, if neces-

sary.

NOTICE

When testing the pressure of the plant when

the regulator is already installed, the pressure

must not exceed the nominal pressure of the

valve by 1.5 times nor the maximum permissi-

ble differential pressure in the actuator.

3.2 Set point adjustment

The control valves and shut-off valves as well

as all consumers or a bypass valve, if appli-

cable, must be opened to allow the maximum

flow rate to be reached.

Turn the restriction (1.1) until the required

flow rate is reached, by reading, for exam-

ple, the flow rate reading off a heat meter (re-

fer to Table 1 · Flow rate set point ranges).

Note: Always start the adjustment from a

closed restriction!

4Turn clockwise to close the restriction. This

reduces the flow rate.

4Turn counterclockwise to open the restric-

tion. This raises the flow rate.

You can also use the adjustment diagrams for

water in Figs. 5 to 7 to help you make the flow

rate adjustment.

EB 3015 EN 9

Operation

In these diagrams, the flow rates are listed by

how many turns of the set point adjustment

are required depending on the differential

pressure at the restriction 0.2 bar or 0.5 bar.

Note: The differential pressure at the restric-

tion

restriction

is fixed at either 0.2 bar or

0.5 bar (see the nameplate).

4Unscrew cap (1.3) and undo lock nut

(1.2). Turn the adjustment screw clockwise

as far as it will go.

4Find the flow set point in the diagram and

determine how many turns are required.

4Turn the screw counterclockwise (based

on a closed restriction) until the selected

set point is adjusted.

4Check the flow rate at the heat meter and

correct, if necessary.

4When the required flow rate is reached,

lock the screw in position with the lock nut

(1.2) and screw cap (1.3) back on.

Lead-seal cap, if necessary.

10 EB 3015 EN

Operation · Set point adjustment

Table 1 · Flow rate set point ranges V

.for water

Type 2423 · Balanced by a bellows

Nominal size DN 15 20 25 32 40 50 65 80 100 125 150 200 250

Differential pressure

at the restriction

Δprestriction = 0.2 bar

Flow rate set point ranges V

.for water in m3/h

0.05

to 2 0.15

to 3 0.25

to 3.5 0.4 to

70.6

to 11 0.9

to 16 2

to 28 3.5

to 35 6.5

to 63 11 to

80 18 to

120 20 to

180 26 to

220

Differential pressure

at the restriction

Δprestriction = 0.5 bar

0.15

to 3 0.25

to 4.5 0.4

to 5.3 0.6

to 9.5 0.9

to 16 2

to 24 3.5

to 40 6.5

to 55 11

to 90 18 to

120 20 to

180 26 to

260 30 to

300

Max. perm. differen-

tial pressure Δp25 bar 20 bar 16 bar 12

bar 10 bar

Nominal size DN 125 150 200 250

Differential pressure

at the restriction

Δprestriction = 0.2 bar

Flow rate set point ranges V

.for water in m3/h

11 to 120 18 to 180 20 to 320 26 to 350

Max. perm. differen-

tial pressure Δp12 bar 10 bar

Type 2423 · Balanced by a diaphragm

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