Samson 2412 Series Service manual

Translation of original instructions
EB 2512 EN
Edition April 2019
Type41-23 Universal Pressure Reducing Valve
Self-operated Pressure Regulators

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.
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
Department (aftersalesser[email protected]).
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.samson.de > Service & Support > Downloads > Documentation.
Denition 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
2 EB 2512 EN

Contents
EB 2512 EN 3
1 Safety instructions and safety measures .........................................................5
1.1 Notes on possible severe personal injury .........................................................8
1.2 Notes on possible personal injury ...................................................................8
1.4 Warning markings on the regulator...............................................................11
2 Markings on the device ...............................................................................12
2.1 Nameplates.................................................................................................12
2.2 Locations of the nameplate ...........................................................................13
2.3 Warnings....................................................................................................13
2.4 Material number..........................................................................................13
2.4.1 Type 2412 Valve..........................................................................................13
2.4.2 Type2413Actuator .....................................................................................13
3 Design and principle of operation ................................................................14
3.1 Technical data .............................................................................................16
4 Measures for preparation before installation ................................................23
4.1 Unpacking ..................................................................................................23
4.2 Transport, lifting and storage ........................................................................23
4.2.1 Transport.....................................................................................................24
4.2.2 Lifting..........................................................................................................24
4.2.3 Storage.......................................................................................................25
5 Assembly....................................................................................................26
5.1 Preparation for installation............................................................................26
5.2 Checking the installation conditions...............................................................27
5.2.1 Mounting position........................................................................................27
5.2.2 Pipeline routing............................................................................................28
5.3 Control line, compensation chamber and needle valve....................................28
5.3.1 Control line .................................................................................................28
5.3.2 Control line kit .............................................................................................28
5.3.3 Compensation chamber................................................................................28
5.3.4 Needle valve ...............................................................................................29
5.4 Additionalttings.........................................................................................31
5.4.1 Strainer.......................................................................................................31
5.4.2 Bypass and shut-off valves ............................................................................31
5.4.3 Insulation ....................................................................................................31
5.4.4 Pressure gauges...........................................................................................32

Contents
4 EB 2512 EN
6 Start-up and operation ................................................................................32
6.1 Start-up.......................................................................................................32
6.1.1 Installing the regulator..................................................................................33
6.1.2 Pipelineushing...........................................................................................34
6.1.3 Pressure test.................................................................................................34
6.2 Operation ...................................................................................................35
6.3 Starting up the plant.....................................................................................35
6.3.1 Regulation of liquids.....................................................................................36
6.3.2 Regulation of steam......................................................................................36
6.4 Adjusting the set point..................................................................................36
7 Maintenance ...............................................................................................37
7.1 Replacing the actuator..................................................................................39
7.2 Replacing the set point springs......................................................................40
7.3 Replacing the seat and plug..........................................................................41
7.4 Replacing the operating diaphragm ..............................................................41
7.5 Tightening torques........................................................................................42
7.6 Lubricants and sealants ................................................................................43
7.7 Accessories .................................................................................................43
7.8 Prepare the regulator for return shipment .......................................................43
7.9 Ordering spare parts and operating supplies .................................................44
8 Malfunctions ...............................................................................................44
9 Decommissioning and removal ....................................................................47
9.1 Decommissioning.........................................................................................47
9.2 Disposal......................................................................................................47
10 Appendix....................................................................................................48
10.1 After-sales service........................................................................................48
10.2 Spare parts .................................................................................................48
10.3 Certicates ..................................................................................................50

EB 2512 EN 5
Safety instructions and safety measures
1 Safety instructions and safety measures
Intended use
TheSAMSONType41-23RegulatorconsistsofaType2412ValveandaType2413Actua-
tor. The valve and actuator (except for tested regulators) are delivered separately and must
be assembled together according to these instructions.
The self-operated regulator is used to control the downstream pressure p2in the pipeline to
the adjusted set point. Liquids, gases and vapors in processing and industrial plants can be
controlled by the regulator.
Theregulatorsaredesignedtooperateunderexactlydenedconditions(e.g.operating
pressure, process medium, temperature). Therefore, operators must ensure that the regulators
areonlyusedinoperatingconditionsthatmeetthespecicationsusedforsizingthedevices
at the ordering stage. In case operators intend to use the regulators in other applications or
conditionsthan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 regulators are 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accessories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 in these instructions
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aretobeobserved.Accord-
ing 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
specializedtraining,theirknowledgeandexperienceaswellastheirknowledgeoftheappli-
cable standards.

6 EB 2512 EN
Safety instructions and safety measures
Personal protective equipment
Werecommendcheckingthehazardsposedbytheprocessmediumbeingused(e.g.
uGESTIS(CLP)hazardoussubstancedatabase).
ÎProvide protective equipment (e.g. safety gloves, eye protection) appropriate for the pro-
cess medium used.
ÎWear hearing protection when working near the regulator.
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.Theymustobserveallhaz-
ard statements, warning and caution notes in these mounting and operating instructions, es-
pecially for installation, start-up and service work.
Wealsorecommendcheckingthehazardsposedbytheprocessmediumbeingused(e.g.
uGESTIS(CLP)hazardoussubstancedatabase).
ÎObservesafetymeasuresforhandlingthedeviceaswellasrepreventionandexplosion
protection measures.
Safety features
TheType41-23Regulatordoesnothaveanyspecialsafetyfeatures.Whenrelievedofpres-
sure, the regulator is opened by the force of the set point springs.
Responsibilities of the operator
The operator is responsible for proper operation and compliance with the safety regulations.
Operators are obliged to provide these mounting and operating instructions as well as the
referenced documents to the operating personnel and to instruct them in proper operation.
Furthermore, the operator must ensure that operating personnel or third persons are not ex-
posed to any danger.

EB 2512 EN 7
Safety instructions and safety measures
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, the operating personnel must be familiar with the applicable
health, safety and accident prevention regulations and comply with them.
Referenced standards and regulations
TheregulatorscomplywiththerequirementsoftheEuropeanPressureEquipmentDirective
2014/68/EU.RegulatorswithaCEmarkinghaveanEUdeclarationofconformity,which
includesinformationabouttheappliedconformityassessmentprocedure.ThisEUdeclaration
ofconformityisincludedintheAppendixoftheseinstructions(seesection10.3).
AccordingtotheignitionriskassessmentperformedinaccordancewithEN13463-1:2009,
section 5.2, 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 Di-
rective 2014/34/EU.
ÎForconnectiontotheequipotentialbondingsystem,observetherequirementsspeciedin
section6.4ofEN60079-14(VDE0165Part1).
Referenced documentation
The following documents apply in addition to these mounting and operating instructions:
−Mounting and operating instructions for
e.g. Acccessories: Compensation chamber uEB2595
e.g. Type2NI Strainer uEB1015
−Data sheets for
e.g. Accessories: Compensation chamber·Screw ttings·Control
line connection·Control line uT2595
e.g. Type2NI Strainer uT1015
−Mounting and operating instructions as well as data sheets for additional components
(e.g. shut-off valves, pressure gauges etc.).

8 EB 2512 EN
Safety instructions and safety measures
1.1 Notes on possible severe personal injury
DANGER
!
Risk of bursting in the regulator.
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.
ÎBeforestartinganyworkontheregulator,depressurizeallplantsectionsconcerned
as well as the regulator.
ÎDrain the process medium from all the plant sections concerned as well as the reg-
ulator.
ÎWear personal protective equipment.
1.2 Notes on possible personal injury
WARNING
!
Crush hazard arising from moving parts.
The regulator contains moving parts (actuator and plug stems as well as set point
spring),whichcaninjurehandsorngersifinsertedintothevalve.
ÎDonotinserthandsorngersbetweenthesetpointspringswhiletheregulatoris
in operation.
ÎBeforeperforminganyworkontheregulator,depressurizetheplant.Disconnector
shut off the external control line.
Damage to health relating to the REACH regulation.
If a SAMSON device contains a substance which is listed as being a substance of very
highconcernonthecandidatelistoftheREACHregulation,thiscircumstanceisindi-
cated on the SAMSON delivery note.
ÎInformation on safe use of the part affected, see uhttp://www.samson.de/reach-
en.html.

EB 2512 EN 9
Safety instructions and safety measures
1.2 Notes on possible personal injury
WARNING
!
Risk of personal injury due to residual process medium in the regulator.
While working on the regulator, residual process medium can escape and, depending
on its properties, may lead to personal injury, e.g. (chemical) burns.
ÎIf possible, drain the process medium from all the plant sections concerned and the
regulator.
ÎWear protective clothing, safety gloves and eyewear.
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 heat up.
ÎWear protective clothing and safety gloves.
Risk of personal injury due to loaded springs.
The set point springs of regulators with adjusted set point are preloaded and are under
tension.
ÎBefore starting any work on the springs, relieve the compression from the preload-
ed springs.
1.3 Notes on possible property damage
NOTICE
!
Risk of regulator damage due to incorrectly attached slings.
ÎDo not attach load-bearing slings to the actuator housing.

10 EB 2512 EN
Safety instructions and safety measures
1.3 Notes on possible property damage
NOTICE
!
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.
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 the surface.
ÎOnly use lubricants approved by SAMSON.When in doubt, consult SAMSON.
Risk of leakage and regulator damage due to excessively high or low tightening
torques.
Observethespeciedtorquesontighteningregulatorcomponents.Excessivelytight-
ened torques lead to parts wearing out quicker. Parts that are too loose may cause
leakage.
ÎObservethespeciedtighteningtorques(seesection7.5).
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 excess pressure damaging plant sections due to construction-related seat
leakage through the regulator.
ÎAlwaystasafetydevice(e.g.safetyexcesspressurevalveorsafetyreliefvalve)in
the plant.