Samson 2333 series Service manual

Mounting and
Operating Instructions
EB 2552-1 EN
Self-operated Pressure Regulators
Type 2333 Pressure Reducing Valve with pilot valve
Edition November 2014
Type2333 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 se-
rious injury
NOTICE
Property damage message or mal-
function
Note:
Additional information
Tip:
Recommended action

2 EB 2552-1 EN

Contents
EB 2552-1 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....................................................................................................9
4.1 Notes on installation ......................................................................................9
4.2 Strainers .....................................................................................................10
4.3 Shut-off valve...............................................................................................10
4.4 Pressure gauges...........................................................................................10
5 Operation...................................................................................................11
5.1 Start-up.......................................................................................................11
5.2 Steam applications.......................................................................................11
5.3 Set point adjustment.....................................................................................11
5.4 Decommissioning.........................................................................................12
6 Maintenance ...............................................................................................13
7 Nameplate..................................................................................................17
8 Technical data.............................................................................................18
9 Dimensions .................................................................................................20
10 Customer service.........................................................................................22

4 EB 2552-1 EN
General safety instructions
1 General safety instructions
−The regulator must 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 valve by the process medium, op-
erating pressure or by moving parts are to be prevented by taking appropri-
ate precautions.
−Proper transport, storage, installation, operation and maintenance are as-
sumed.

EB 2552-1 EN 5
Process medium and scope of application
2 Process medium and scope of application
Pressure regulators for set points from 2 to 28bar · Valve nominal sizes DN125 to 400 · Nom-
inal pressure PN16 to 40 · Suitable for liquids, gases and vapors up to 350°C
The differential pressure across the regulator is used as auxiliary energy to operate the valve.
To open the regulator, this pressure must be at least as high as the minimum differential pres-
sure ∆pmin specied in Table 1.
The mounted pilot valve (pressure reducing valve) determines the function of the regulator.
WARNING!
Risk of uncontrolled excess pressure in the plant.
Risk of bursting!
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 temperature outside the ambient temperature
range.
Do not remove the protective caps from the valve ports until immediately before installing the
valve into the pipeline.
When regulators are too heavy to be lifted by hand, fasten the lifting sling at a suitable place
on the valve body.
WARNING!
Do not attach lifting slings or supports to mounting parts, such as control line, pilot
valve etc.
The valve can fall or mounting parts may be damaged.
Securely fasten slings or supports to the valve body and secure against slipping.

6 EB 2552-1 EN
Design and principle of operation
3 Design and principle of op-
eration
See Fig.1 and Fig.2.
The medium ows through the globe valve (1)
in the direction indicated by the arrow. The
position of the plug determines the ow rate
across the area released between plug (3)
and valve seat (2). The travel position of the
pilot valve (5) determines the pressure condi-
tions across the valve.
The forces created by the upstream pressure
p1acting on the plug surface and by the con-
trol pressure pSacting on the balancing bel-
lows (4) or balancing diaphragm (11) and
the force of positioning spring (3.1) are com-
pared.
In the Type 2333 Pressure Reducing Valve, a
rise in downstream pressure p2causes the pi-
lot valve to close. The control pressure pSin-
creases, and the plug of the main valve starts
to close. When the pilot valve is closed (p
S
=
p1), the pressure reducing valve (main valve)
is also completely closed.
Together with the pilot valve, the xed restric-
tion (8) or the Venturi nozzle (6) create the
control pressure pS.
If the downstream pressure p
2
falls again be-
low the set point, the pilot valve opens. The
control pressure pSfalls as a result. The force
resulting from the upstream pressure p
1
acting
on the plug surface causes the valve to open.
To ensure proper functioning, the minimum
differential pressure ∆pmin listed in Table 1
must be available as specied depending on
the eld of application.
The regulator version for steam is only avail-
able with valves balanced by a bellows. This
version has a condensation chamber (10) al-
ready tted in the control line. The needle
valve (9) is open and lead-sealed.
Before start-up, ll the condensation chamber
with water at the top ller opening.
Table 1: Minimum differential pressure ∆pmin
Nominal size DN125 DN150 DN200 DN250 DN300 DN400
Minimum
differential
pressure ∆pmin
Valve balanced by
a bellows for steam
applications
1.9bar 2.0bar 1.4bar 1.4bar – –
Valve balanced by a
bellows for air/water 1.0bar 1.0bar 0.7bar 0.7bar – –
Valve balanced by a
diaphragm 0.8bar 0.8bar 0.4bar 0.4bar 0.5bar 0.3bar

EB 2552-1 EN 7
Design and principle of operation
Type2333 Pressure Reducing Valve· Type 2422 Valve, balanced by a bellows·DN125 to 250
1
2
3
3.1
4
5
7
10
p1p2
8
9
Version suitable for steam
Version suitable for liquids and gases
1 Globe valve (main valve)
2Valve seat
3 Plug with plug stem
3.1 Positioning spring
4 Balancing bellows
5 Pilot valve
6 Venturi nozzle (for gases and liquids)
7 Strainer
8 Fixed restriction (version for steam)
9 Needle valve (version for steam)
10 Condensation chamber (only for steam or medium
temperatures above 150°C)
pSControl pressure
p1Upstream pressure
p2Downstream pressure
Fig.1: Functional diagram of valve balanced by a bellows
4
5
7
6
Lower section
with bellows Pilot valve
Type 2422 as main
valve balanced by a
bellows
Lower section
with bellows Pilot valve
pS
pS

8 EB 2552-1 EN
Design and principle of operation
Type2333 Pressure Reducing Valve· Type 2422 Valve, balanced by a diaphragm·DN125 to 400
1Valve body (main valve)
2Valve seat
3 Plug with plug stem
3.1 Positioning spring
5 Pilot valve
6 Venturi nozzle
7 Strainer
11 Balancing diaphragm
pSControl pressure
p1Upstream pressure
p2Downstream pressure
Fig.2: Functional diagram of valve balanced by a diaphragm
65
7
1233.1 11
p
1p2
Diaphragm section
Pilot valve
Type2422 as main
valve, balanced by a
diaphragm
pS

EB 2552-1 EN 9
Installation
4 Installation
See Fig.3.
Select the installation location making sure
that the regulator is installed at a distance of
at least six times the nominal size (DN) away
from pipe ttings, instruments or ow diver-
sions. They can change the ow conditions
which may lead to an instable control pro-
cess especially in applications with gases, air
or steam.
Contact SAMSON to obtain the TV-SK17041
documentation which contains more details on
installation requirements.
4.1 Notes on installation
Install the ready-assembled regulator in hori-
zontal pipelines.
−Flush and clean the pipeline thorough-
ly before installing the regulator. Other-
wise, impurities in the pipeline may im-
pair the proper functioning of the valve,
above all the tight shut-off.
−Direction of ow must match the direc-
tion indicated by the arrow on the body.
−Install the regulator free of stress. If nec-
essary, support the pipeline near to the
connecting anges. Do not attach sup-
ports directly to the valve or actuator.
−Install a strainer upstream of the regu-
lator.
−Protect the regulator from icing up when
controlling media that can freeze. If nec-
essary, depressurize and drain the reg-
ulator and remove it from the pipeline
while the plant is shut down.
Note:
The side on which the operating ele-
ments (hook-up of the pilot valve) are
located varies depending on whether
a valve balanced by a bellows or a di-
aphragm is used.
Mounting position
Valve balanced by a bellows
−Bellows including housing
suspended downward
Valve balanced by a diaphragm
−Balancing diaphragm (diaphragm sec-
tion) pointing upward
Insulation · To insulate cold systems, we rec-
ommend rst lling the plant and carefully
rinsing it (see section 5.1). The regulator must
not be insulated until the set point is adjusted.
−Start up the plant and adjust the set
point. Shut down the plant again and let
it warm up until the condensation water
has dried off.
−Afterwards, insulate the regulator and
pipes conveying the process medi-
um using insulation material with a wa-
ter vapor barrier. If the pilot valve has
a spring, it must must be protected by a
sleeve to allow it to move. The spring-
loaded actuator stem must not touch the
insulation.



10 EB 2552-1 EN
Installation
Fig.3: Installation example for Type 2333 Pressure Reducing Valve
1 Shut-off valve
2 Upstream pressure gauge
3 Strainer
5 Downstream pressure gauge
6Shut-off valve
9Venturi nozzle
10 Strainer in the pilot valve line
Thermal insulation
Note:
Do not insulate the pilot valve as well
in applications with medium tempera-
tures above 80°C.
Pressure testing of the plant · The pressure
must not exceed the maximum permissible
pressure of the regulator and plant on test-
ing the pressure of the plant when the regula-
tor is already installed. An excessive test pres-
sure can damage the balancing bellows or di-
aphragm. If necessary, remove the regulator
from the pipeline or isolate the regulator in the
pipeline and install a bypass.
4.2 Strainers
Install the strainer (e.g. SAMSON Type1/
Type 2) upstream of the pressure reducing
valve.
−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.
Tip:
Remember to leave enough space to
remove the lter element.
4.3 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 peri-
ods of time.
4.4 Pressure gauges
Install a pressure gauge both upstream and
downstream of the regulator to monitor the
pressures prevailing in the plant.

12 345
6
10
98
p1p2
Type 2422 as
main valve
Type 2333
Pressure
Reducing Valve
Pilot valve

EB 2552-1 EN 11
Operation
5 Operation
See Fig.1 and Fig.2.
5.1 Start-up
First start up the regulator after mounting all
parts (e.g. valve and control line). Open con-
trol line with needle valve and check to ensure
it is connected correctly.
Rinsing the plant · After lling the plant, rst
completely open the consumer and adjust the
regulators to achieve the maximum ow rate.
Rinse out the pipeline at full ow rate for sev-
eral minutes. Check the installed strainer (e.g.
by measuring the pressure drop). Clean the
strainer, if necessary.
−Slowly ll the plant. Make sure that the
pressure rises simultaneously upstream
and downstream of the regulator to
avoid damaging the balancing bellows/
diaphragm.
−Open all the valves on the consum-
er side. Slowly open the shut-off valves
starting on the ow pipe side in small
steps waiting a few minutes inbetween.
5.2 Steam applications
Observe the following points for applications
with steam:
−Before start-up, all pipes conveying the
process medium must be completely
drained and dry (to prevent steam ham-
mering).
−Before start-up, ll the condensation
chamber (10) with water (also at the pi-
lot valve, if necessary).
−Slowly start up the plant and allow time
for the pipes and valves to warm up.
−Air and condensate must be allowed to
escape from the plant. Install steam trap
(e.g. SAMSON Type13 E) or air vent for
steam-operated systems (e.g. SAMSON
Type3) at a suitable location.
5.3 Set point adjustment
See Fig.1 and Fig.2.
Adjust the required downstream pressure set
point while the plant (consumer) is open by
turning the set point adjuster at the pilot valve
(5).
When the adjusted downstream pressure set
point is reached, the pilot valve closes, caus-
ing the main valve to close as well.
Turn clockwise (P):
−The set point pressure increases.
Turn counterclockwise (Q):
−The set point pressure is reduced.
The pressure gauge located on the down-
stream pressure side allows the adjusted set
point to be monitored.
First set the minimum set point by turning the
set point adjuster counterclockwise (Q).
Wait until the pressure reducing valve starts
to regulate before adjusting the set point by
slowly turning the adjuster clockwise (P).

12 EB 2552-1 EN
Operation
NOTICE
Incorrectly adjusted set point or set
point cannot be adjusted.
Malfunction!
Start by turning the set point adjust-
er by one turn at a time and wait until
the downstream pressure reaches the
set point. As soon as the pressure re-
ducing valve starts to work, you can
adjust the set point by making larg-
er changes. Wait several minutes un-
til the pressure conditions have stabi-
lized and check the set point. Correct
the set point, if necessary.
After start-up and set point adjustment, avoid
fast changes in pressure.
5.4 Decommissioning
Depressurize the plant. Close the shut-off
valves starting from the ow side (high-pres-
sure line).

EB 2552-1 EN 13
Maintenance
6 Maintenance
The regulator does not require any mainte-
nance. Nevertheless, it is subject to natural
wear, particularly at the seat, plug and oper-
ating diaphragm.
Depending on the operating conditions, check
the regulator at regular intervals to avoid pos-
sible malfunctions.
WARNING!
Performing work on pressurized or hot
plant sections:
Hot process medium can escape un-
controlled on dismantling the regula-
tor. Risk of scalding!
Allow the regulator to cool down be-
fore depressurizing and draining it to
remove it from the pipeline.
Details on faults and how to remedy them can
be found in Table 2.
The listed examples of malfunctions are
caused by mechanical faults in the main valve
or pilot valve as well as incorrect regulator
sizing.
In the simplest case, the functioning can be re-
stored following the recommended action. To
repair the pilot valve, read the operating in-
structions for the corresponding regulator (pi-
lot valve). As in many cases, special tools are
required, we advise you to contact SAMSON
after-sales service to nd out how to proceed
to repair the regulator or replace a component
(see section 10).
Exceptional operating and installation condi-
tions can lead to changed situations that may
affect the control response and lead to mal-
functions. In such cases, check the installa-
tion conditions, process medium, temperature
and pressure conditions. A thorough analy-
sis may often require the on-site assistance of
SAMSON after-sales service.
The table is not intended to be exhaustive as
there are diverse reasons for malfunctions.

14 EB 2552-1 EN
Maintenance
Table 2: Troubleshooting
Malfunction Possible reasons Recommended action Comments
Malfunction only occurs when the consumer is closed or during low load:
Downstream
pressure is much
higher than the
adjusted set point
Pilot valve · Leakage between
seat and plug
Remove valve from the pipeline
and clean seat and plug. Re-
new plug, if necessary.
Otherwise, return regulator to
SAMSON for repair.
Install a shut-off valve instead of
the pilot valve. If the main valve
closes when the shut-off valve
is closed, the pilot valve has
caused the malfunction.
Main valve · Leakage be-
tween seat and plug
Remove valve from the pipeline
and clean seat and plug. Re-
new plug, if necessary.
Otherwise, return regulator to
SAMSON for repair.
Malfunction occurs when the consumer is open or at maximum load:
Downstream
pressure is much
higher than the
adjusted set point
The pilot valve does not func-
tion.
Balancing bellows/dia-
phragm defective. Medium
leaks from the actuator.
Replace the defective compo-
nent.
Install a shut-off valve instead of
the pilot valve. If the main valve
closes when the shut-off valve
is closed, the pilot valve has
caused the malfunction.
Pilot valve seized up
Clean the pilot valve. Apply
grease to plug stem guides,
if necessary. Replace defec-
tive parts.
Main valve seized up Clean main valve.
Install a shut-off valve instead of
the pilot valve. If the main valve
does not close when the shut-off
valve is closed, the main valve
has caused the malfunction.
Balancing bellows/dia-
phragm of the main valve
defective
Replace bellows/diaphragm.
Install a shut-off valve instead of
the pilot valve. If the main valve
does not close when the shut-off
valve is closed, the main valve
has caused the malfunction. Par-
ticularly in steam applications,
steam hammering can dam-
age the bellows. Therefore, make
sure that no water or conden-
sate is present in the pipeline be-
fore start-up.
In steam applications: plant
started up too quickly.
Fill condensation chambers
with water. Slowly start up the
plant.

EB 2552-1 EN 15
Maintenance
Troubleshooting (continued)
Malfunction Possible reasons Recommended action Comments
The required
downstream
pressure is not
reached
Strainer in the line in which
the pilot valve is installed is
clogged up
Clean strainer.
The required minimum differ-
ential pressure to operate the
regulator is not available
Raise upstream pressure or re-
duce downstream pressure
Set point range of the pilot
valve is too low Convert or replace pilot valve.
Main valve seized up Clean main valve.
Install a shut-off valve instead of
the pilot valve. If the main valve
does not open when the shut-off
valve is opened, the main valve
has caused the malfunction.
Pilot valve seized up
Clean pilot valve. Clean inter-
nal control line used to tap the
downstream pressure.
Install a shut-off valve instead of
the pilot valve. If the main valve
does not open when the shut-off
valve is opened, the main valve
has caused the malfunction.
Needle valve installed be-
tween xed restriction and
main valve is jammed or
closed.
Clean the needle valve. Check
setting (open).
Main valve is sized to be too
small (KVS/CV)
Resize the valve. Replace main
valve.
Regulator's
reaction is
sluggish
Strainer in the line in which
the pilot valve is installed is
clogged up.
Clean strainer.
Inside the pilot valve is
clogged up, impairing the
ow through the valve
Clean inside the pilot valve.
Needle valve installed be-
tween xed restriction and
main valve is jammed.
Clean the needle valve. Check
setting (open).
The xed restriction is
clogged up. Clean xed restriction.
Control line or Venturi noz-
zle blocked Clean parts. Improve steam conditioning, if nec- essary.

16 EB 2552-1 EN
Maintenance
Troubleshooting (continued)
Malfunction Possible reasons Recommended action Comments
Control loop
hunts
KVS/CVof pilot valve too
large (after valve has been re-
placed).
Install pilot valve with suitable
KVS/CV coefcient.
The ow conditions in the
plant at the location where the
regulator is installed are not
suitable for the regulator.
Pipe reducers, instruments
and diversions can change
the ow conditions which may
lead to an instable control
process especially in applica-
tions with gases, air or steam.
Refer to the SAMSON docu-
ment TV-SK 17041 for mini-
mum distances.
If this is the case, send a sketch of
the plant to SAMSON for a thor-
ough analysis.
KVS/CVof main valve too
large
Resize the valve. Replace main
valve or convert it to another
KVS/CV coefcient.
Occasional vibrational excita-
tion originating from the plant Contact SAMSON.
Possibly change the natural fre-
quency, e.g. over the needle valve
(9) when there is resonance in the
plant.

EB 2552-1 EN 17
Nameplate
SAMSON
DN
bar
Made in Germany
˚C
T
bar
∆p
PN
Kvs
No
No
∆p
Made in Germany
Size
SAMSON psi
Npsi T˚F Cv Cl
12
910 11
8
5
4
1
3
2
9
810 11 12
5
4
1
3
2
DIN version
ANSI version
7 Nameplate
Nameplate of main valve
Valve
1Valve type
2 Model number
3 Model number index
4 Order number or date
5KVS coefcient
8 Nominal size
9 Nominal pressure
10 Perm. differential pressure in bar
11 Perm. temperature in °C
12 Body material
For ANSI version
5Valve size
8 Perm. differential pressure in psi
9Perm. temperature in °F
10 Body material
11 CV coefcient (KVS x 1.17)
12 ANSI Class (pressure rating)
Fig.4: Nameplate of Type 2333 Pressure Reducing Valve

18 EB 2552-1 EN
Technical data
8 Technical data
Table 3: Technical data · All pressures in bar (gauge)
Type2422 Valve·Balanced by a bellows·Suitable for liquids, gases or vapors
Nominal size DN125 DN150 DN200 DN250
Nominal pressure PN16 to 40
KVS coefcient 200 360 520 1) 620 1)
KVSI (with ow divider St I) 150 270 400 1) 500 1)
KVSIII (with ow divider St III) 100 180 260 1) 310 1)
xFZ value 0.35 0.3 0.3 0.3
Minimum differential pressure Δpmin
For vapors 1.9bar 2.0bar 1.4bar 1) 1.4bar 1)
For gases and liquids 1.0bar 1.0bar 0.7bar 1) 0.7bar 1)
Max. permissible differential pressure ∆pmax 16bar 12bar 10bar 1) 10bar 1)
Leakage class according to IEC60534-4 ≤ 0.05 % of KVS coefcient 2)
Max. permissble temperature (depending on
the pilot valve)
Type 50 ES: 50 °C·Type 44-2: 150 °C·Type 44-0 B:200 °C
Type 44-1B: 150 °C·Type 41-23: 150 °C 3)·Type2405: 150°C
Set point ranges in bar, continuously adjust-
able at the pilot valve
Type 50 ES: 2.5 to 6, 4 to 10·Type 44-2: 2 to 4.2, 2.4 to 6.3, 6 to
10.5·Type 44-0 B/44-1 B: 2 to 6, 4 to 10, 8 to 20
Type2405: 2 to 5, 4.5 to 10
Type 41-23: 2 to 5, 4.5 to 10, 8 to 16, 10 to 22, 20 to 28
1) Version with reduced KVS coefcient possible. Same technical data as DN150
2) ≤0.1% of KVS coefcient with metal-seated plug
3) Version for steam up to 350°C

EB 2552-1 EN 19
Technical data
Type2422 Valve·Balanced by a diaphragm·Suitable for liquids and gases
Nominal size DN125 DN150 DN200 DN250 DN300 DN400
Nominal pressure PN 16 to 40
KVS coefcient 250 380 650 1) 800 1) 1250 2000
xFZ value 0.35 0.35 0.3 1) 0.3 1) 0.2 0.2
Minimum differential pressure
Δpmin
0.8 bar 0.8bar 0.4 bar 1) 0.4 bar 1) 0.5 bar 1) 0.3bar
Max. permissible differential
pressure ∆pmax
12 bar 12bar 10bar 1) 10 bar 1) 10 bar 1) 6 bar
Leakage class according to
IEC60534-4 ≤ 0.01 % of KVS coefcient
Max. permissble temperature (de-
pending on the pilot valve)
Type 50 ES: 50 °C·Type 44-2: 150 °C·Type 44-0 B/44-1 B: 150°C
Type2406: 150°C·Type 41-23: 150 °C· Steam pressure reducing valve as
special version on request
Set point ranges in bar, continu-
ously adjustable at the pilot valve
Type 50 ES: 2.5 to 6, 4 to 10·Type 44-2: 2 to 4.2, 2.4 to 6.3, 6 to
10.5·Type 44-0 B/44-1 B: 2 to 6, 4 to 10, 8 to 20 bar Type2405: 2 to 5,
4.5 to 10·Type 41-23: 2 to 5, 4.5 to 10, 8 to 16, 10 to 22, 20 to 28
1) Version with reduced KVS coefcient possible. Same technical data as DN150

20 EB 2552-1 EN
Dimensions
9 Dimensions
H1
H2
H3
H
Type 2422 Valve ·DN125 to 250·Balanced by a bellows
Nominal size DN 125 DN 150 DN 200 DN 250
Length L 400mm 480mm 600mm 730mm
Height H 285mm 315mm 390mm 390mm
Height H1 460mm 590mm 730mm 730mm
Height H2 145mm 175mm 235mm 260mm
Max. height H32) ≤ 725mm ≤ 825mm ≤ 890mm ≤ 890mm
Weight 1) (PN 16 with
Type50ES Pilot Valve) 75kg 118kg 260kg 305kg
1) +10 % for cast iron 1.0619/PN25 and spheroidal graphite iron EN-JS1049/PN25
2) Depending on the pilot valve used
Fig.5: Dimensions and weights∙Type 2422 Valve balanced by a bellows