Samson 45-6 Service manual

Differential Pressure Regulator

Type 45-6

Mounting and

Operating Instructions

EB 3226 EN

Edition March 2008

Type 45-6 (0.1 to 1 bar, DN 15)

Contents Page

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

2 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

2.1 Mounting position . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

2.2 Strainer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

2.3 Shut-off valves, gauges . . . . . . . . . . . . . . . . . . . . . . . . . 6

3 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

3.1 Start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

3.2 Set point adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . 6

4 Maintenance – Replacing parts . . . . . . . . . . . . . . . . . . . . . 7

4.1 Cleaning and replacing the plug . . . . . . . . . . . . . . . . . . . . 7

4.2 Replacing the diaphragm . . . . . . . . . . . . . . . . . . . . . . . . 8

5 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

6 Nameplate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

7 Customer inquiries . . . . . . . . . . . . . . . . . . . . . . . . . . 10

8 Dimensions and weights . . . . . . . . . . . . . . . . . . . . . . . 11

2EB 3226 EN

Contents

Note!

These Mounting and Operating Instructions EB 3226 EN refer to the Type 45-6 Differential

Pressure Regulator manufactured from July 2005 onward (0075, see nameplate).

EB 3226 EN 3

Safety instructions

General safety instructions

The differential pressure regulator must be installed, started up and serviced

by skilled or semi-skilled staff in accordance with good engineering practice

so that employees and third persons are not exposed to danger.

All safety instructions and warnings given in these mounting and operating

instructions, particularly those concerning installation, start-up, and

maintenance, must be strictly observed.

The regulator complies with the requirements of the European Pressure

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

regulator bearing the CE marking includes information on the applied

conformity assessment procedure and is provided on request.

To ensure appropriate use, only use the regulator in applications where the

operating pressure and temperatures do not exceed the operating values

specified in the order.

Note that the manufacturer does not assume any responsibility for damage

caused by external forces or any other external factors. Take appropriate

safety precautions to prevent hazards that may be caused by the process

medium, the operating pressure, or moving parts in the regulator.

Make sure the regulator is shipped and stored properly.

Important!

Depending on the field of application, allow the regulator to cool down or

warm up to reach ambient temperature prior to starting any work on the

regulator. Always depressurize the relevant section of the plant and, if

necessary, also drain the pipeline prior to removing the regulator from the

pipeline.

When carrying out a pressure test on the section of the plant equipped with

a pressure regulator, prevent the actuator from being damaged by the test

pressure.

Protect the regulator against frost if it is used to control freezing media.

Note! Non-electrical control valves, whose valve bodies are not lined with

an insulating material coating, do not have their own potential ignition

source according to the ignition 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

operation

The differential pressure regulator consists of

a valve with a balanced plug and of an

opening actuator with an operating dia-

phragm and a spring assembly.

The differential pressure regulator is de-

signed to maintain the differential pressure

at the adjusted set point. The valve opens as

the differential pressure rises.

The differential pressure to be controlled is

transmitted to the operating diaphragm

(6.1), where it is converted into a force. For

this purpose, the downstream pressure (low

pressure) is directed through the hole in the

valve body (11.1) to the top (low-pressure)

diaphragm chamber of the actuator. The

4EB 3226 EN

Design and principle of operation

Fig. 1 · Sectional drawing

1 Valve body

1.1 Connection nut

1.2 Stopper (version for DN 32 to 50)

2 Seat

3 Valve plug (pressure balanced)

3.1 Plug nut

3.2 Guide nipple of plug

3.3 Screw ferrule (DN 32 to 50)

3.4 Plug stem

4 Nut of diaphragm plate

5 Diaphragm plate

6 Actuator

6.1 Operating diaphragm

7 Screws

8 Positioning spring(s)

9 Spring plate

10 Set point adjuster

11 Control line1)

11.1 Hole in the valve body

12 Manual adjuster

Tightening torques

Item DN Nm

1.2 Stopper 15 to 25

32 to 50 70

110

3.1 Valve plug 15 to 25

32 to 50 4

3.3 Screw ferrule 32 to 50 110

7 Screw 15 to 32

40 to 50 8

p1p2

1.2

1.1

3.4

11.1

3.1

3.2

3.3

6.1

Type 45-6 with screwed ends

(DN 40/50)

Manual adjuster

(0.1 to 1 bar, DN 15 to 32)

1) Control line turned into plane of projection.

It is routed in front of the valve and connected to the high-pressure chamber (p1).

upstream pressure (high pressure) is routed

through the attached control line (11) to act

on the diaphragm in the high-pressure

chamber.

The differential pressure creates a force at

the operating diaphragm (6.1) which is

used to position the plug depending on the

force of the positioning springs (8). The

force of the spring assembly is modified by

turning the set point adjuster (10).

The principle of operation described above

also applies to regulators with a manual ad-

juster (0.1 to 1 bar, DN 15 to 32). The posi-

tioning springs, however, are located in an

enclosed housing. The set point is adjusted

at the manual adjuster (12) using the scale.

Note!

For external connection of the control lines

(special version) observe the following steps:

Connect the high-pressure line of the plant to

the high-pressure connection (+) of the actua-

tor (bottom diaphragm chamber)

Connect the low-pressure line of the plant to

the low-pressure connection (–) of the actua-

tor (top diaphragm chamber) as illustrated

in Fig. 1 (left).

2 Installation

2.1 Mounting position

The differential pressure regulators must be

installed in horizontal bypass or short-circuit

pipes with the actuator suspended down-

ward (see Fig. 2).

Regulators in sizes DN 15 to DN 25 can

also be installed in vertical pipelines. For

medium temperatures above 80 °C, the reg-

ulator must not be installed with the dia-

phragm actuator pointing upward. The me-

dium must flow through the valve in the di-

rection indicated by the arrow on the body.

2.2 Strainer

Since sealing parts, globules, and other im-

purities carried along by the medium may

impair the proper functioning of the valve

and especially the tight shut-off, a strainer

(e.g. SAMSON Type 1NI) must be installed

upstream of the differential pressure regula-

tor.

The strainer must be installed so that the me-

dium flows through it in the direction indi-

cated by the arrow on the strainer body.

The filter element must be suspended down-

ward. Ensure that there is sufficient space

available to remove the filter.

EB 3226 EN 5

Installation

Fig. 2 · Installation examples

344

1 Strainer

2 Regulator 3 Shut-off valve

4 Pressure gauge

Installation in a short-circuit pipe

Installation in a bypass pipe

2.3 Shut-off valves, gauges

We recommend the installation of hand-op-

erated shut-off valves both upstream of the

strainer and downstream of the regulator.

This allows the plant to be shut down for

cleaning and maintenance routines or when

it is not operated for extended periods. In-

stall pressure gauges upstream and down-

stream of the valve to monitor the pressures

prevailing in the plant.

3 Operation

3.1 Start-up

Fill the plant very slowly on start-up. When

pressure-testing the pipelines with the regu-

lator installed, make sure the test pressure

does not exceed 1.5 times the nominal pres-

sure.

3.2 Set point adjustment

The required differential pressure is adjusted

at the set point adjuster (10) or the manual

adjuster (12) by loading the spring(s).

4Turn the adjuster clockwise to increase

the differential pressure.

4Turn the adjuster counterclockwise to

reduce the differential pressure.

In the case of regulators with set point

ranges from 0.1 to 1 bar in sizes DN 15 to

32, the positioning springs are located in

the actuator housing,

The set point can be adjusted directly at the

manual adjuster (12) on the basis of the

scale value (see Fig. 5).

One turn of the manual adjuster will change

the differential pressure by 0.033 bar.

Note!

Do not adjust the set point to a scale value

smaller than “1”!

Under certain conditions, the set point can-

not be adjusted anymore as a result.

In this case, the following steps are recom-

mended:

– Relieve the process pressure from both

sides of the regulator.

– Turn the manual adjuster counterclockwise

as far as it will go to its lowest position.

– Turn the manual adjuster back clockwise

at least past the scale value “1” to “2”.

– The regulator can now be readjusted.

6EB 3226 EN

Operation

0.2

0.4

0.6

0.8

1.0

1.2

0123456

Δp

Fig. 3 · Set point adjustment according to scale

Division of scale

Fig. 4 · Manual adjuster (0.1 to 1 bar / DN 15 to 32)

Set point adjustment

using the

manual adjuster

4 Maintenance – Replacing

parts

The regulator is maintenance-free, but is

subject to wear and tear, especially at the

seat, plug and operating diaphragm.

Depending on the application conditions

that prevail, the regulator must be inspected

at appropriately scheduled intervals to pre-

vent any problems before they occur.

Details on faults and the recommended

action can be found in the table on page 8.

If a problem cannot be solved with the help

of the information specified in the table,

contact SAMSON. In order to replace the

plug and operating diaphragm, proceed as

described in sections 4.1 and 4.2.

Caution!

To carry out any work on the differ-

ential pressure regulator, you have

to remove the device from the pipe-

line. For this purpose, first allow the

relevant section of the plant to cool

down in the case of high tempera-

tures. Then, depressurize and drain

this section prior to removing the regu-

lator.

4.1 Cleaning and replacing the

plug

– Refer to Fig. 1 on page 4 –

Caution!

The positioning springs are pre-loaded.

Take appropriate precautionary measures: if

necessary, make a disassembly tool or use

SAMSON’s disassembly tool 9129-2747.

1. Remove regulator from the pipeline.

Unscrew control line (11).

2. Disassemble positioning springs (8).

3. Unscrew stopper (1.2).

4. Loosen body screws (7) and remove ac-

tuator.

5. Unscrew plug nut (3.1) and remove

valve plug (3) from plug stem.

6. For valve sizes DN 15 to 25, unscrew

and remove the guide nipple of the plug

(3.2) using a socket wrench (order no.

1280-3001).

For valve sizes DN 32 to 50, first re-

move screw ferrule (3.3) and then pull

out guide nipple (3.2).

7. Clean seat and plug assembly thor-

oughly. Check control line, screw con-

nections, and hole (11.1) for any block-

ages.

Should the plug be damaged, replace

the entire plug assembly.

Replace the seat if it is damaged.

To reassemble the regulator, proceed in re-

verse order.

Make sure that the diaphragm is inserted

properly in the body groove before fasten-

ing the components.

Refer to tightening torques listed in the table

in Fig. 1.

EB 3226 EN 7

Maintenance – Replacing parts

4.2 Replacing the diaphragm

– Refer to Fig. 1 on page 4 –

Caution!

The positioning springs are pre-loaded.

Take appropriate precautionary measures: if

necessary, make a disassembly tool or use

SAMSON’s disassembly tool 9129-2747.

1. Disassemble positioning springs (8).

2. Unscrew control line (11).

3. Loosen screws (7) and lift off actuator.

4. Unscrew nut (4) sealed with paint while

holding lower nut stationary.

5. Lift off diaphragm plate (5) and replace

operating diaphragm (6.1).

To reassemble, proceed in reverse order.

Make sure that the diaphragm is inserted

properly in the body groove before fasten-

ing the components.

Refer to tightening torques listed in the table

in Fig. 1.

8EB 3226 EN

Maintenance – Replacing parts

5 Troubleshooting

EB 3226 EN 9

Troubleshooting

Fault Possible cause Solution

Differential

pressure set

point is

exceeded

Valve too large for con-

trol task Recalculate the valve sizing flow coefficient,

KVS, and contact SAMSON.

Seat and plug untight Remove valve, clean seat and plug. If neces-

sary, replace plug (section 4.1). Otherwise,

return the device to SAMSON for repair.

Operating diaphragm

defective Replace diaphragm (section 4.2) or return

the device to SAMSON for repair.

Control line blocked Remove control line and clean it.

Differential

pressure set

point is not

reached

Valve too small for con-

trol task Check set point range and contact

SAMSON.

Safety device, e.g. pres-

sure limiter, has been

triggered

Check plant, unlock safety device.

Insufficient pressure drop

across the plant Compare existing differential pressure across

the plant with the plant’s drag.

Strainer blocked Drain and clean filter of the strainer.

Wrong installation of

valve Reinstall the valve in such a way that the

medium flows through the valve in the direc-

tion indicated by the arrow.

Control loop

hunts Valve too large for

control task Recalculate the valve sizing flow coefficient,

KVS, and contact SAMSON.

6 Nameplate 7 Customer inquiries

In case of inquiries, please submit the fol-

lowing details:

4Regulator type and nominal size

4Thread or flange connection

4Model number

4Upstream and downstream pressures

4Flow rate in m3/h

4Has a strainer been installed?

4Installation diagram

10 EB 3226 EN

Nameplate

Fig. 5 · Nameplate

810 9

1 Model number

2 Configuration ID

3 Year of manufacture

4 Type designation

5 Nominal pressure PN or ANSI Class

6 Flow coefficient KVS or CV

7 Max. perm. temperature °C or °F

8 Set point range,

differential pressure in bar or psi

9 Max. perm. differential pressure Δp

10 Arrow indicating direction of flow

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