Samson 45-6 User manual

Differential Pressure Regulator

Type 45-6

Mounting and

Operating Instructions

EB 3 26 EN

Edition January 2004

Fig. 1 ⋅Type 45-6

Contents Page

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

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

2.1 Installation position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

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

2.3 Shut-off valves, pressure gauges . . . . . . . . . . . . . . . . . . . . . . . 5

3Operation

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

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

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

4 Maintenance  Replacement . . . . . . . . . . . . . . . . . . . . . . . . . 6

4.1 leaning or replacing the plug . . . . . . . . . . . . . . . . . . . . . . . . 7

4.2 Replacing the diaphragm . . . . . . . . . . . . . . . . . . . . . . . . . . 7

5 Troubles ooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

6 Description of t e nameplate . . . . . . . . . . . . . . . . . . . . . . . . . 9

7 Customer inquiries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

8 Dimensions and weig ts . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Contents

2EB 3126 EN

General safety instructions

Only fully trained and qualified personnel may mount, start up, and service

the device, o serving the accepted industry codes and practices. Make sure

employees or third persons are not exposed to any danger.

All safety instructions and warnings in these instructions, particularly those

concerning installation, start-up, and maintenance, must e strictly o served.

The regulator fulfills the requirements of the European Pressure Equipment Di-

rective 97/23/EC. Valves with a CE marking have a declaration of conform-

ity that includes information on the applied conformity assessment procedure.

The declaration of conformity can e viewed and downloaded on the Internet

at http://www.samson.de.

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

cations where the operating pressure and temperatures do not exceed the op-

erating values ased on the valve sizing data su mitted in the order.

Note that the manufacturer does not assume any responsi ility for damage

caused y external forces or any other external influences.

Any hazards which could e caused in the regulator y the process medium,

the operating pressure, or moving parts are to e prevented y means of ap-

propriate measures.

Proper shipping and appropriate storage are assumed.

Caution!

Prior to removing the regulator from the pipeline, always depressurize the rele-

vant section of the plant and drain the pipeline if the process medium is a

liquid. If necessary, allow the regulator to cool down or heat up to reach am-

ient temperature prior to starting any work on the regulator.

Protect the regulator against frost when controlling freezing media.

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

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

according to the risk assessment stipulated in EN 13463-1: 2001, paragraph

5.2, even in the rare incident of an operating fault. Therefore, such valve ver-

sions do not fall within the scope of Directive 94/9/EC.

EB 3126 EN 3

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 medium flows through the valve in

the direction indicated by the arrow. The

pressure in the valve outlet (low pressure),

transmitted via the attached control line

(10), acts on the lower diaphragm cham-

ber. The high pressure, transmitted through

Fig. 2 ⋅Sectional drawing

1Valve body

2Seat

3Plug

4Nut

5Diaphragm plate

6 Operating diaphragm

7Screws

8 Positioning spring(s)

9 Set point adjuster

10 ontrol line

11 Bore

10 11

Tightening torques

DN Nm

Item 3 Plug 15...25

32...50

110

Item 4 Nut 15...25

32...50

Item 7 Screws 15...32

40...50

4EB 3126 EN

Design and principle of operation

the bore (11) in the valve body, acts on the

upper diaphragm chamber of the actuator.

The differential pressure creates a position-

ing force at the operating diaphragm which

is used to position the plug depending on

the force of the positioning springs (8). The

force of the spring assembly, i.e. the set

point, is modified by turning the set point

adjuster (9).

2Installation

2.1 Installation position

The differential pressure regulators must be

installed in horizontal bypass or short-cir-

cuit pipes with the actuator suspended

downward (see Fig. 3).

Regulators in sizes DN 15 to DN 25 can be

installed in vertical pipelines, too. For me-

dium temperatures above 80 ° , the regulator

must not be installed with the diaphragm actu-

ator pointing vertically upward. The medium

must flow through the valve in the direction in-

dicated by the arrow on the valve 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

(SAMSON Type 1NI) must be installed up-

stream of the differential pressure regulator.

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.

2.3 S ut-off valves, pressure

gauges

We recommend the installation of hand-

operated shut-off valves both upstream of

the strainer and downstream of the regula-

tor. This allows the plant to be shut down

for cleaning and maintenance routines or

when it is not operated for extended

periods.

Install pressure gauges upstream and down-

stream of the valve to monitor the pressures

prevailing in the plant.

Fig. 3 ⋅Installation examples

1Shut-off valve

2Strainer

3Regulator

4 Pressure gauge

–

+–

Installation in a short-circuit pipe

Installation in a bypass pipe

EB 3126 EN 5

Installation

3Operation

3.1 Start-up

Fill the plant very slowly on start-up.

When pressure-testing the pipelines with the

regulator installed, make sure the test pres-

sure does not exceed 1.5 times the nominal

pressure.

3.2 Set point adjustment

The required differential pressure is ad-

justed at the set point adjuster (9) which

loads the spring(s).

Turn the set point adjuster clockwise to

increase the differential pressure.

Turn the set point adjuster counterclock-

wise to reduce the differential pressure.

4 Maintenance  Replacement

The regulator is maintenance-free, but is

subject to wear and tear, especially at the

seat, plug, and operating diaphragm. De-

pending on the application conditions that

prevail, the regulator must be inspected at

appropriately scheduled intervals to prevent

any problems before they occur. Details on

faults and how to correct them 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

If you intend to carry out any work

on the differential pressure regula-

tor, you are required to remove the

device from the pipeline. For this

purpose, first allow the relevant sec-

tion of the plant to cool down in

case of high temperatures. Then,

depressurize and drain this section

prior to removing the regulator.

6EB 3126 EN

Operation

4.1 Cleaning or replacing t e plug

1. Disassemble springs (8).

Caution!

The springs are pre-loaded. Take proper

precautionary measures or, if necessary,

make a disassem ly tool.

2. Unscrew the control line (10).

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

4. For valve sizes DN 15 to 25, unscrew

and remove the guide nipple with plug

(3) using a socket wrench (order no.

1280-3001).

The wrench can be made, for example,

from a Gedore screwdriver bit (IN 19-

19) by boring a 17 mm hole with a 17

mm diameter into the 19 mm hexagon

bit.

For valve sizes DN 32 to 50, first

remove the stopper and then pull out

the plug.

5. lean seat and plug thoroughly. heck

control line and screw connections and

bore (11) for any blockages.

Should the plug be damaged, replace

the entire plug.

To reassemble the regulator, 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. 2.

4.2 Replacing t e diap ragm

1. Disassemble springs (8).

Caution!

The springs are pre-loaded. Take proper

precautionary measures or, if necessary,

make a disassem ly tool.

2. Unscrew control line (10).

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 and replace

diaphragm.

6. To reassemble, proceed in reverse

order.

Make sure that the diaphragm is in-

serted properly in the body groove be-

fore fastening the components.

Refer to tightening torques listed in the

table in Fig. 2.

Fig. 4 ⋅Socket wrench

Ø 17

SW 19

19 mm hexagon bit

EB 3126 EN

Maintenance  Replacement

5 Troubles ooting

Fault Possible cause Solution

Differential

pressure set

point is

exceeded

Valve too large for

control task

Recalculate the valve sizing flow coefficient,

KVS, and contact SAMSON.

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

necessary, replace plug (section 4.1).

Otherwise, return device for repair.

Operating diaphragm

defective

Replace diaphragm (section 4.2) or return the

device to SAMSON for repair.

ontrol line plugged Remove control line and clean it.

Differential

pressure set

point is not

reached

Valve too small for

control task

heck set point range and contact SAMSON.

Safety device, e.g.

pressure limiter, has

been triggered

heck plant, unlock safety device.

Insufficient pressure

drop across the plant

ompare existing differential pressure in 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

direction indicated by the arrow.

ontrol loop

hunts

Valve too large for

control task

Recalculate the valve sizing flow coefficient,

KVS, and contact SAMSON.

8EB 3126 EN

Troubleshooting

6 Description of t e nameplate 7 Customer inquiries

In case of inquiries, please submit the follow-

ing details:

Regulator type and nominal size

Thread or flange connection

Model number

Upstream and downstream pressures

Flow rate in m3/h

Has a strainer been installed?

Installation diagram

Fig. 5 ⋅La eling

1Model number

2Index

3Date

4Type designation

In the other fields:

Nominal pressure PN or ANSI lass

coefficient

Max. perm. temperature ° or °F

Set point range: differential pressure in bar

or psi

Max. perm. differential pressure ∆p

EB 3126 EN 9

Description of the nameplate

8 Dimensions and weig ts

ØD

L3 L3

onnection nuts with

flanges Flanged body DN 40 and 50

onnection nuts with

threaded ends

onnection nuts with

weld-on fittings

10 EB 3126 EN

Dimensions and weights

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