Samson 2404-2 Service manual

Translation of original instructions
EB 2540 EN
Type2404-2 Excess Pressure Valve with Pilot Valve
Self-operated regulator for small set point ranges
Edition May 2023

Definition of signal words
Hazardous situations which, if not avoided,
will result in death or serious injury
Hazardous situations which, if not avoided,
could result in death or serious injury
Property damage message or malfunction
Additional information
Recommended action
DANGER
!
WARNING
!
NOTICE
!
Note
Tip
EB 2540 EN
Note on these mounting and operating instructions
These mounting and operating instructions assist you in mounting and operating the device
safely. The instructions are binding for handling SAMSON devices. The images shown in
these instructions are for illustration purposes only. The actual product may vary.
ÎFor the safe and proper use of these instructions, read them carefully and keep them for
later reference.
ÎIf you have any questions about these instructions, contact SAMSON‘s After-sales Service
([e-mail]).
The mounting and operating instructions for the devices are included
in the scope of delivery. The latest documentation is available on our
website at www.samsongroup.com > Service & Support > Downloads >
Documentation.

Contents
EB 2540 EN
1 Safety instructions and measures ................................................................1-1
1.1 Notes on possible severe personal injury ......................................................1-4
1.2 Notes on possible personal injury ................................................................1-5
1.3 Notes on possible property damage.............................................................1-6
2 Markings on the device ..............................................................................2-1
2.1 Nameplates................................................................................................2-1
2.1.1 Nameplate of main valve.............................................................................2-1
2.1.2 Actuator nameplate.....................................................................................2-2
2.1.3 Nameplate of pilot valve..............................................................................2-2
2.1.4 Nameplate of input pressure regulator..........................................................2-3
2.2 Location of the nameplates ..........................................................................2-4
2.3 Materialidenticationnumber .....................................................................2-5
2.3.1 Type2406asmainvalve.............................................................................2-5
2.3.2 Type2422asmainvalve.............................................................................2-5
2.3.3 Type2420Actuator ....................................................................................2-5
2.3.4 Type2406PilotValve..................................................................................2-5
2.3.5 Type2441InputPressureRegulator..............................................................2-5
3 Design and principle of operation ...............................................................3-1
3.1 Additionalttings........................................................................................3-3
3.2 Technical data ............................................................................................3-4
4 Shipment and on-site transport ...................................................................4-1
4.1 Accepting the delivered goods .....................................................................4-1
4.2 Removingthepackagingfromtheregulator ..................................................4-1
4.3 Transporting and lifting the regulator............................................................4-2
4.3.1 Transporting the regulator............................................................................4-2
4.3.2 Lifting the regulator .....................................................................................4-3
4.4 Storing the regulator ...................................................................................4-4
5 Installation.................................................................................................5-1
5.1 Installation conditions..................................................................................5-1
5.2 Preparationforinstallation...........................................................................5-3
5.1 Mounting ...................................................................................................5-3
5.1.1 Installing the regulator.................................................................................5-4
5.1.2 Cleaning the pipeline ..................................................................................5-4
5.2 Testing the regulator ....................................................................................5-5
5.2.1 Leakage .....................................................................................................5-5
5.2.2 Pressuretest................................................................................................5-6
5.3 Insulation ...................................................................................................5-6

Contents
EB 2540 EN
6 Start-up .....................................................................................................6-1
6.1 Start-up and putting the device back into operation .......................................6-2
7 Operation..................................................................................................7-1
7.1 Adjusting the set point.................................................................................7-1
8 Malfunctions ..............................................................................................8-1
8.1 Troubleshooting ..........................................................................................8-1
8.2 Emergency action .......................................................................................8-4
9 Servicing....................................................................................................9-1
9.1 Preparingthevalveforservicework .............................................................9-2
9.2 Installing the regulator after service work ......................................................9-3
9.3 Service work...............................................................................................9-3
9.4 Ordering spare parts and operating supplies ................................................9-4
10 Decommissioning .....................................................................................10-1
11 Removal ..................................................................................................11-1
11.1 Removingtheregulatorfromthepipeline....................................................11-1
11.2 Removingtheactuatorfromthevalve .........................................................11-1
12 Repairs ....................................................................................................12-1
12.1 ReturningdevicestoSAMSON ..................................................................12-1
13 Disposal...................................................................................................13-1
14 Certicates...............................................................................................14-1
15 Annex......................................................................................................15-1
15.1 Tightening torques.....................................................................................15-1
15.2 Lubricants.................................................................................................15-1
15.3 Tools ........................................................................................................15-1
15.4 Accessories ..............................................................................................15-1
15.5 Spare parts ..............................................................................................15-1
15.6 After-sales service.....................................................................................15-2

EB 2540 EN 1-1
Safety instructions and measures
1 Safety instructions and measures
Intended use
TheSAMSONType2404-2Regulatorisanexcesspressurevalvewithpilotvalveforsmall
setpointranges.ItconsistsofaType2406Valve(DN65to150)orType2422Valveasthe
mainvalvewithaType2420DiaphragmActuator(DN200to400),Type2406PilotValve
andtheType2441InputPressureRegulator.Theassembledunitistestedbeforedelivery.
The self-operated regulator is used to control the pressure in storage tanks. Gases in process-
ing and industrial plants can be controlled by the regulator.
Theregulatorisdesignedtooperateunderexactlydenedconditions(e.g.operatingpres-
sure, process medium, temperature). Therefore, operators must ensure that the regulator is
onlyusedinoperatingconditionsthatmeetthespecicationsusedforsizingtheregulatorat
the ordering stage. In case operators intend to use the controllers in applications or condi-
tionsotherthanthosespecied,contactSAMSON.
SAMSON does not assume any liability for damage resulting from the failure to use the de-
viceforitsintendedpurposeorfordamagecausedbyexternalforcesoranyotherexternal
factors.
ÎRefertothetechnicaldataandnameplateforlimitsandeldsofapplicationaswellas
possible uses.
Reasonably foreseeable misuse
The regulator is not suitable for the following applications:
−Useoutsidethelimitsdenedduringsizingandbythetechnicaldata
−Useoutsidethelimitsdenedbytheadditionalttingsmountedontheregulator
Furthermore, the following activities do not comply with the intended use:
−Use of non-original spare parts
−Performingserviceandrepairworknotdescribed
Qualications of operating personnel
The regulator must be mounted, started up, serviced and repaired by fully trained and quali-
edpersonnelonly;theacceptedindustrycodesandpracticesmustbeobserved.According
to these mounting and operating instructions, trained personnel refers to individuals who are
abletojudgetheworktheyareassignedtoandrecognizepossiblehazardsduetotheirspe-
cializedtraining,theirknowledgeandexperienceaswellastheirknowledgeoftheapplica-
ble standards.

1-2 EB 2540 EN
Safety instructions and measures
Personal protective equipment
Werecommendcheckingthehazardsposedbytheprocessmediumbeingused(e.g.
uGESTIS(CLP)hazardoussubstancesdatabase).Dependingontheprocessmediumand/
or the activity, the protective equipment required includes:
−Protectiveclothing,safetyglovesandeyeprotectioninapplicationswithhot,coldand/or
corrosive media
−Wear hearing protection when working near the valve
−Hard hat
−Safety harness, e.g. when working at height
−Safetyfootwear,ifapplicableESD(electrostaticdischarge)footwear
ÎCheck with the plant operator for details on further protective equipment.
Revisions and other modications
Revisions,conversionsorothermodicationsoftheproductarenotauthorizedbySAMSON.
Theyareperformedattheuser'sownriskandmayleadtosafetyhazards,forexample.Fur-
thermore, the product may no longer meet the requirements for its intended use.
Warning against residual hazards
To avoid personal injury or property damage, plant operators and operating personnel must
preventhazardsthatcouldbecausedintheregulatorbytheprocessmedium,theoperating
pressureorbymovingpartsbytakingappropriateprecautions.Plantoperatorsandoperat-
ingpersonnelmustobserveallhazardstatements,warningsandcautionnotesinthese
mounting and operating instructions.
Hazardsresultingfromthespecialworkingconditionsattheinstallationsiteoftheregulator
mustbeidentiedinariskassessmentandpreventedthroughthecorrespondingsafetyin-
structions drawn up by the operator.
Wealsorecommendcheckingthehazardsposedbytheprocessmediumbeingused(e.g.
uGESTIS(CLP)hazardoussubstancesdatabase).
ÎObservesafetymeasuresforhandlingthedeviceaswellasrepreventionandexplosion
protection measures.
These mounting and operating instructions deals with the standard version of the device.
Components of the device that differ to those used for the standard version described in this
documentcanbeexchangedwithothercertainSAMSONcomponents.Theresidualhazards
of these components are described in the associated mounting and operating instructions
(seedocumentslistedunder'Referenceddocumentation').

EB 2540 EN 1-3
Safety instructions and measures
Safety features
TheType2404-2Regulatordoesnothaveanyspecialsafetyfeatures.Whenrelievedof
pressure, the regulator is closed by the force of the set point springs.
Responsibilities of operating personnel
Operating personnel must read and understand these mounting and operating instructions as
wellasthereferenceddocumentsandobservethespeciedhazardstatements,warnings
and caution notes. Furthermore, operating personnel must be familiar with the applicable
health, safety and accident prevention regulations and comply with them.
Responsibilities of the operator
Operators are responsible for proper use and compliance with the safety regulations. Opera-
tors are obliged to provide these mounting and operating instructions as well as the refer-
enced documents to the operating personnel and to instruct them in proper operation. Fur-
thermore,operatorsmustensurethatoperatingpersonnelorthirdpartiesarenotexposedto
any danger.
Operatorsareadditionallyresponsibleforensuringthatthelimitsfortheproductdenedin
the technical data are observed. This also applies to the start-up and shutdown procedures.
Start-up and shutdown procedures fall within the scope of the operator's duties and, as such,
are not part of these mounting and operating instructions. SAMSON is unable to make any
statements about these procedures since the operative details (e.g. differential pressures and
temperatures) vary in each individual case and are only known to the operator.
Referenced standards, directives and regulations
TheregulatorscomplywiththerequirementsoftheEuropeanPressureEquipmentDirective
2014/68/EUandtheMachineryDirective2006/42/EC.RegulatorswithaCEmarking
have a EU declaration of conformity which includes information about the applied conformi-
tyassessmentprocedure.ThisEUdeclarationofconformityisincludedinthe'Certicates'
section.
AccordingtotheignitionhazardassessmentperformedinaccordancewithClause5.2of
ISO80079-36,thenon-electricalregulatorsdonothavetheirownpotentialignitionsource
even in the rare incident of an operating fault. As a result, they do not fall within the scope of
Directive2014/34/EU.
ÎForconnectiontotheequipotentialbondingsystem,observetherequirementsspeciedin
Clause6.4ofEN60079-14(VDE0165-1).

1-4 EB 2540 EN
Safety instructions and measures
Referenced documentation
The following documents apply in addition to these mounting and operating instructions:
−Mounting and operating instructions for
e.g. Type2N or 2NI Strainer uEB1015
e.g. Type2406 Excess Pressure Valve uEB2522
e.g. Type 2441 Pressure Reducing Valve uEB2626-1
−Mountingandoperatinginstructionsaswellasdatasheetsforadditionalttings(e.g.
shut-off valves, pressure gauges etc.).
1.1 Notes on possible severe personal injury
DANGER
!
Risk of bursting in pressure equipment.
Regulatorsandpipelinesarepressureequipment.Impermissiblepressureorimproper
opening can lead to regulator components bursting.
ÎObservethemaximumpermissiblepressureforregulatorandplant.
ÎIf necessary, a suitable overpressure protection must be installed on site in the plant
section.
ÎBeforestartinganyworkontheregulator,depressurizeallplantsectionsaffected
as well as the regulator.
ÎDraintheprocessmediumfromalltheplantsectionsaffectedaswellastheregula-
tor.
ÎWear personal protective equipment.

EB 2540 EN 1-5
Safety instructions and measures
1.2 Notes on possible personal injury
WARNING
!
Risk of personal injury through incorrect operation, use or installation as a result of
information on the regulator being illegible.
Over time, markings, labels and nameplates on the regulator may become covered
withdirtorbecomeillegibleinsomeotherway.Asaresult,hazardsmaygounno-
ticed and the necessary instructions not followed. There is a risk of personal injury.
ÎKeep all relevant markings and inscriptions on the device in a constantly legible
state.
ÎImmediately renew damaged, missing or incorrect nameplates or labels.
Risk of burn injuries due to hot or cold components and pipelines.
Dependingontheprocessmedium,regulatorcomponentsandpipelinesmaygetvery
hot or cold and cause burn injuries.
ÎAllow components and pipelines to cool down or warm up to the ambient tempera-
ture.
ÎWear protective clothing and safety gloves.
Risk of hearing loss or deafness due to loud noise.
The noise emissions depend on the valve version, plant facilities and process medium.
ÎWear hearing protection when working near the valve.
Risk of personal injury due to pressurized components and process medium being
discharged.
Incorrect opening of pressure equipment or mounting parts may lead to the process
medium escaping to the atmosphere.
ÎDonotloosenthecontrollinewhilethevalveispressurized.

1-6 EB 2540 EN
Safety instructions and measures
WARNING
!
Damage to health relating to the REACH regulation.
If a SAMSON device contains a substance listed as a substance of very high concern
onthecandidatelistoftheREACHregulation,thisisindicatedontheSAMSONdeliv-
ery note.
ÎInformation on safe use of the part affected uwww.samsongroup.com/en/
about-samson/material-compliance/reach-regulation/.
1.3 Notes on possible property damage
NOTICE
!
Risk of regulator damage due to contamination (e.g. solid particles) in the pipeline.
The plant operator is responsible for cleaning the pipelines in the plant.
ÎFlush the pipelines before start-up.
Risk of regulator damage due to the use of unsuitable lubricants.
The lubricants to be used depend on the regulator material. Unsuitable lubricants may
corrode and damage surfaces.
ÎOnly use lubricants approved by SAMSON.
When in doubt, consult SAMSON.
Risk of regulator damage due to incorrectly attached slings.
ÎDonotattachload-bearingslingstotheactuatorhousing.
Risk of regulator damage due to unsuitable medium properties.
Theregulatorisdesignedforaprocessmediumwithdenedproperties.
ÎOnlyusetheprocessmediumspeciedforsizingtheequipment.

EB 2540 EN 1-7
Safety instructions and measures
NOTICE
!
Risk of leakage and regulator damage due to excessively high or low tightening
torques.
Observethespeciedtorqueswhentighteningregulatorcomponents.Excessivetight-
eningtorquesleadtopartswearingoutmorequickly.Partsthataretooloosemay
cause leakage.
ÎObservethespeciedtighteningtorques(see'Tighteningtorques'inAnnex).
Risk of regulator damage due to the use of unsuitable tools.
Certain tools are required to work on the regulator.
ÎOnly use tools approved by SAMSON.
When in doubt, consult SAMSON.
Risk of the process medium being contaminated through the use of unsuitable lubri-
cants and/or contaminated tools and components.
ÎKeep the regulator and the tools used free from solvents and grease.
ÎMake sure that only suitable lubricants are used.
Risk of excess pressure damaging plant sections due to construction-related seat
leakage through the regulator.
ÎAlwaysinstallasafetydevice(e.g.safetyexcesspressurevalveorsafetyrelief
valve) in the plant.
SAMSON's After-sales Service can support you concerning lubricant, tightening torques
and tools approved by SAMSON.
Note

1-8 EB 2540 EN
Safety instructions and measures

EB 2540 EN 2-1
Markings on the device
2 Markings on the device
Severalnameplatesareafxedtothedevice.Thenameplatesareusedtoidentifythesepa-
rate regulator components.
2.1 Nameplates
2.1.1 Nameplate of main valve
Type2406 Valve·DN65 to 150
9
8
7
6
12
10 11 12 13
3
5
1517
16
14 4
18 19
20
21
Type2422 Valve·DN200 to 400
9
8
7
12
10 11 12 13
3
5
1517
16
14 4
18 19
20
21
Fig.2-1: Nameplates of Type2406 and Type2422 Valves (main valves)
1Max.perm.operating
pressure at the actuator
2Materialno./congurationID
3 Type
4Productionnumber
5 KVS/CV
6 Set point range
7Valvesize
8Pressurerating
9Perm.differentialpressure
10 Perm.temperature
11 Bodymaterial
12 Serial number (if applicable)
13 TÜVregistrationno.(ifexists)
14 DataMatrixcode
15 CEmarking(DN32to50)
16 Country of origin
17 EAC, if applicable
18 UKCA, if applicable
19 Year of manufacture
20 Month of manufacture
21 IDofthecerticationbody
1Modelnumberwithindex
2Materialnumber/congura-
tionID
3 Type
4Productionnumber
5 KVS/CV
7Valvesize
8Pressurerating
9Perm.differentialpressure
10 Perm.temperature
11 Bodymaterial
12 Serial number
13 TÜVregistrationno.
14 DataMatrixcode
15 CE marking
16 Country of origin
17 EAC, if applicable
18 UKCA, if applicable
19 Year of manufacture
20 Month of manufacture
21 IDofthecerticationbody

2-2 EB 2540 EN
Markings on the device
2.1.2 Actuator nameplate
132
771011 12
6.2 4
99 13
14
15
Fig.2-2: Actuator nameplate
2.1.3 Nameplate of pilot valve
9
8
7
6
12
10 11 12
13
3
5
1517
16
14 4
18 19
20
21
Fig.2-3: Nameplate of Type2406 Pilot Valve
1 Actuator area
2 Actuator model
2.1 Valvemodel
3 Material number and device
index
4IDnumber
6.2 Max.perm.pressureat
actuator
7Valvesize
9 Set point range
10 Diaphragmmaterial
11 Country of origin
12 UKCA, if applicable
13 Year of manufacture
14 Month of manufacture
15 CE marking
1Max.perm.operating
pressure at the actuator
2Materialnumber/
congurationID
3 Type
4Productionnumber
5 KVS/CV
6 Set point range
7Valvesize
8Pressurerating
9Perm.differentialpressure
10 Perm.temperature
11 Bodymaterial
12 Serial number (if
applicable)
13 TÜVregistrationno.(if
applicable)
14 DataMatrixcode(if
applicable)
15 CEmarking(DN32to50)
16 Country of origin
17 EAC, if applicable

EB 2540 EN 2-3
Markings on the device
2.1.4 Nameplate of input pressure regulator
1Pressurerating:
DIN:PN·ANSI:CL·JIS:K
2CongurationID(Var.-ID)anddeviceindex
3 Order number or year of manufacture
4 Type designation
5Threadsize/valvesize:
DIN:DN·ANSI:NPS·JIS:DN…A/B
6Flowcoefcient:
DIN:KVS·ANSI:CV·JIS:CV
7Perm.temperature:
DIN:°C·ANSI:°F·JIS:°C/°F
8Set point range:
DIN:bar·ANSI:psi·JIS:bar/psi
9Max.perm.differentialpressureΔp:
DIN:bar·ANSI:psi·JIS:bar/psi
10 Arrowindicatingthedirectionofow
2 4
3 1
657
8 9
10
Fig.2-4: Nameplate of Type2441 Input Pressure Regulator

2-4 EB 2540 EN
Markings on the device
2.2 Location of the nameplates
Location of the
nameplate on the
main valves
Location of the
nameplate on the
input pressure
regulator
Location of the
nameplate on the
pilot valve
Fig.2-5: Nameplates of the main valves, pilot valve and assembled regulator

EB 2540 EN 2-5
Markings on the device
2.3 Material identication
number
2.3.1 Type2406 as main
valve
Seethenameplate(11forDIN/ANSIver-
sion, body material) for the material used.
Specifying the material number, you can
contactustondoutmoredetails.
For more details on the nameplate, see sec-
tion2.1.
2.3.2 Type2422 as main
valve
Seethenameplate(11forDIN/ANSIver-
sion, body material) for the material used.
Specifying the material number, you can
contactustondoutmoredetails.
For more details on the nameplate, see sec-
tion2.1.
2.3.3 Type2420 Actuator
Specifying the material number, you can
contactustondoutwhichmaterialisused.
Itisspeciedonthenameplateinthe'MNo.'
eld(3).Formoredetailsonthenameplate,
seesection2.1.2.
2.3.4 Type2406 Pilot Valve
Seethenameplate(11forDIN/ANSIver-
sion, body material) for the material used.
Specifying the material number, you can
contactustondoutmoredetails.
For more details on the nameplate, see sec-
tion2.1.3.
2.3.5 Type2441 Input
Pressure Regulator
The material is indicated on the cast body.
Specifying the material number, you can
contactustondoutmoredetails.
For more details on the nameplate, see sec-
tion2.1.4.

2-6 EB 2540 EN
Markings on the device

EB 2540 EN 3-1
Design and principle of operation
3 Design and principle of oper-
ation
ÎSeeFig.3-1
The following components interact to regu-
late the pressure of the inert gas.
The input pressure regulator (3) is delivered
ready-adjusted. It reduces the supply pres-
sure p (medium: inert gas or compressed air)
to the input pressure pefor the pilot valve (2)
toapprox.1bar/15psi(positivepressure),
ensuring precise pressure control even at
varying upstream pressures.
The pilot valve (2) compares the actual pres-
sure with the set point pressure. In the idle
state, the pilot valve is closed by the force of
the set point spring (2.1).
The upstream pressure p1to be controlled is
routed to the pilot valve over the control line
(2.4). The force created by the upstream
pressure p1at the operating diaphragm
(2.2) is compared with the adjusted spring
force of the set point spring. The pilot valve
opens when the blanketing gas pressure in
the tank rises above the adjusted set point.
This causes the control pressure pSto in-
crease as well. The main valve also starts to
open when the force of the control pressure
pSacting on the actuator diaphragm (1.2) in
the main valve (1) is greater than the force of
the closing spring (1.1). As a result, the
blanketing gas is vented to the atmosphere
or recovered for processing until the tank
blanketingisre-stabilizedorthepressure
falls below adjusted set point.
The needle valve (4) is delivered ready-ad-
justed and lead-sealed.
Optionally, the outlet (
1
/
8
NPT) of the needle
valve (4) can be routed to the downstream
pressure (p2) side of the main valve.
Note

3-2 EB 2540 EN
Design and principle of operation
32.4
4
1.1
2.2
1.2
1
p2
pS
p1
p1
pe
p
2.1
2
2.3
2.5
Pilot valve
Inert gas
Tank
To atmosphere or
recovered for
processing
Needle valve (lead-
sealed setting)
Input pressure
regulator
Main valve
1 Main valve
1.1 Closing spring
1.2 Operating diaphragm
(main valve)
2Pilotvalve
2.1 Set point spring
2.2 Operating diaphragm
(pilot valve)
2.3 Set point adjuster (screw
SW27/1
1
/
8
“)
2.4 Control line
2.5 Cap
3Input pressure regulator
(xedsetting)
4Needle valve (lead-
sealed setting)
p Supply pressure
p1
Upstream pressure
(blanketing gas pressure)
p2Downstreampressure
pSControl pressure
pe
Input pressure (pilot
valve)
Fig.3-1: Functional diagram (based on DN100)·Regulator in NPS2½ to 16/DN65 to 400