Samson 41-23 Series Service manual

Mounting and
Operating Instructions
EB 2512 EN
Translation of original instructions
Edition March 2016
Type 41-23 Pressure Reducing Valve
Self-operated Pressure Regulators
Type41-23 Universal 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 seri-
ous injury
NOTICE
Property damage message or mal-
function
Note:
Additional information
Tip:
Recommended action

2 EB 2512 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.
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]).

Contents
EB 2512 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 ..................................................................5
4 Installation ....................................................................................................6
4.1 Assembly ......................................................................................................6
4.2 Mounting position..........................................................................................8
4.3 Control line, compensation chamber and needle valve......................................9
4.4 Strainer(lter)..............................................................................................10
4.5 Shut-off valve...............................................................................................10
4.6 Pressure gauge ............................................................................................10
5 Operation ...................................................................................................11
5.1 Start-up.......................................................................................................11
5.2 Adjusting the set point..................................................................................11
5.3 Decommissioning.........................................................................................12
6 Cleaning and maintenance .......................................................................... 13
6.1 Replacing the operating diaphragm ..............................................................13
7 Customer inquiries ......................................................................................15
8 Dimensions .................................................................................................15
9 Nameplate ..................................................................................................17
10 Technical data .............................................................................................18

4 EB 2512 EN
General safety instructions
1 General safety instructions
−The regulator is to 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 personnel
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. Devices with a CE marking have a declaration of
conformity, which includes information about the applied conformity assess-
ment procedure. This declaration of conformity can be provided 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 regulator by the process medium,
operating pressure or by moving parts are to be prevented by taking appro-
priate precautions.
−Proper transport, storage, installation, operation and maintenance are as-
sumed.

EB 2512 EN 5
Process medium and scope of application
2 Process medium and scope of application
Pressure regulators for set points from 0.05 to 28bar · Valve nominal sizes DN15 to 100
Nominal pressure PN16 to 40 · Suitable for liquids, gases and vapors up to 350°C
The valve closes when the downstream pressure rises.
NOTICE
The Type41-23 Pressure Reducing Valve is not a safety valve. If necessary, 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frost,duringstorageandtransportation.
When regulators are too heavy to be lifted by hand, fasten the lifting sling at a suitable place
on the valve body.
NOTICE
Do not attach any lifting equipment, slings or supports to mounting parts, such as the
adjusting screw or control line.
3 Design and principle of operation
See Fig.1 on page7.
TheType41-23PressureReducingValveconsistsofaType2412ClosingValveanda
Type2413Actuator.Thevalveandactuatoraredeliveredseparatelyandmustbeassembled
accordingtotheinstructionsinsection4.1.
The pressure reducing valve is used to maintain the pressure downstream of the valve to an
adjusted set point.
Theprocessmediumowsthroughthevalvebetweenseat(2)andplug(3)inthedirectionin-
dicatedbythearrowonthebody.Thepositionofthevalveplugdeterminestheowrate
and the pressure ratio across the valve. The plug stem is sealed by a frictionless bellows
(5.1).Thedownstreampressurep2istransmittedthroughthecompensationchamber(18)
andcontrolline(17)totheoperatingdiaphragm(12)whereitisconvertedintoapositioning
force. For actuator versions with a bellows, the pressure is transmitted to the operating bel-

6 EB 2512 EN
Installation
lows(12.1).Thepositioningforceisusedto
move the valve plug according to the force of
thepositioningsprings(7).Thespringforce
isadjustableatthesetpointadjuster(6).
Valves with KVS4andhigherfeatureabal-
ancingbellows(4).Theupstreampressure
acts on the outside of the bellows and the
downstream pressure on the inside of the
bellows. As a result, the forces produced by
the upstream and downstream pressures act-
ing on the plug are balanced.
Depending on the valve and actuator used,
the regulator can be upgraded to create a
pressurereducingvalveforlowowrates,a
steam pressure reducing valve or a pressure
reducing valve with increased safety.
4 Installation
4.1 Assembly
See Fig.1 on page7.
Valve and actuator can be assembled before
or after the valve has been installed in the
pipeline.
Pushthediaphragmactuator(10)withactu-
atorstem(11)throughtheholeinthecross-
beam(8)ontothespigotsofthebellows
(5.1).Alignitandfastenwithnuts(width
acrossats16,9)ontothevalveange(ap-
prox.25Nm).
For metal bellows actuators in DN15 to 50,
removethecrossbeam(8)fromthevalve.
Pushtheactuatorstem(11)ontothespigots
ofthebellows(5.1).Alignthepillars(8.1)
andfastenwithnuts(widthacrossats24,
8.2)totheactuator(max.60Nm).
For metal bellows actuators in DN65 to
100,removethecrossbeam(8)fromthe
valveandunscrewthepillars(8.1).Screw
thepillarsintothethreadedholes(8.3)ofthe
actuatorangeasfarastheywillgo.Push
theactuatorwithactuatorstem(11)ontothe
spigotsofthebellows(5.1).Fastenthepillars
withnuts(widthacrossats24,8.2)ontothe
valveange(max.60Nm).
1 Valve body
2 Seat
3 Plug
4 Balancing bellows
5 Plug stem
5.1 Bellows
6 Set point adjuster
7 Positioning springs
8 Crossbeam
8.1 Pillar
8.2 Nuts for pillar
8.3 Threaded holes
9 Fastening nuts
10 Diaphragm actuator
11 Actuator stem
12 Operating diaphragm
12.1 Operating bellows
13 Diaphragm plate
14 Nut
15 Nuts and bolts
16 Control line connection G ¼ (for steam including
screwjointwithrestriction)
17 Control line installed on site (control line kit avail-
able for tapping the pressure directly at the valve
body,seeT2595)
18 Compensation chamber
19 Filler plug
20 Anti-rotation clip

EB 2512 EN 7
Installation
2
3
4
5
6
7
5.1
10
11
12
16
18
19
17
1
8
9
15
20
13 14
12.1
8.2 8.2
8.1
8.2
(25 Nm)
(40 Nm)
8.3
Fig.1: Functional diagram
Table1: Assignment of compensation chamber (18) to
regulator
Actuator area A in
cm²
Item number∙Compensation chamber
DN15 to 50 DN65 to 250
640 1190-8789 1190-8790
320 1190-8788 1190-8789
160/80/40 1190-8788
DN65to100
Type2413 Actuator with metal
bellowsfor2to6bar,5to10bar,
20to28barand10to22bar
DN15to50
Type 2412 Valve
Type2413
Diaphragm Actuator
Item 14: Apply Loctite 272 sealant
(SAMSONorderno.8121-4000)to
the bottom section of thread on the
actuator stem during assembly.
NOTICE: this does not apply to version
for oxygen service or the FDA-
compliant version.

8 EB 2512 EN
Installation
4.2 Mounting position
NOTICE
Protect the regulator from icing up
when controlling media that can
freeze. Remove the regulator from
the pipeline when the plant is shut
down if the regulator is not installed
areas free from frost.
Flush the pipeline thoroughly before install-
ing the regulator to ensure that any sealing
parts, weld spatter and other impurities car-
ried along by the process medium do not im-
pair the proper functioning of the valve,
above all the tight shut-off.
NOTICE
Install a strainer (e.g. SAMSON
Type2) upstream of the regulator.
Install the pressure reducing valve in hori-
zontal pipelines. On installing the valve,
makesurethedirectionofowcorresponds
with the arrow on the body. For media with
a tendency to condensate, install the pipeline
with a slight downward slope on both sides
so that the condensate can drain properly. If
the pipeline upstream and downstream of
the valve run vertically upwards, an auto-
matic water drainage (e.g. SAMSON
Type13ESteamTrap)isrequired.Choosea
place of installation that allows you to freely
access the regulator even after the entire
plant has been completed. The regulator
must be installed free of stress. If necessary,
supportthepipeneartheconnectingang-
es.
Standard mounting position
for gases, liquids and steam
Not for millibar pressure
regulator
(A=1200cm²)
Alternative mounting position
for gases and liquids at medium
temperatureupto80°C
Prescribed mounting position
for millibar pressure regulators
(A=1200cm²)
Not for steam
Not permissible! 1)
1) On request: Permissible for
regulatorswithxedplugstemguide
plus with medium temperature up to
80°C.Notforsteam.
Fig.2: Mounting position
NOTICE
Do not attach supports directly to the
valve or actuator.
If a bypass line is to be used, it must be con-
nected downstream of the pressure tapping
point. Install a shut-off valve in the bypass
line.
Note:
Do not install any instruments (e.g.
temperature regulators or shut-off
valves) that restrict the cross-section
of the pipe between the pressure tap-
ping point and the valve.


EB 2512 EN 9
Installation
4.3 Control line, compensation
chamber and needle valve
Control line · A control line must be provid-
ed at the site of installation, e.g. a
3
/
8
“ pipe
forsteamoran8x1or6x1mmpipefor
air/water.
Connect the control line to the downstream
line (p2)atleastonemeterawayfromthe
valveoutlet(Fig.3.1).Ifamanifoldislocat-
ed downstream of the pressure reducing
valve(Fig.3.2),connectthevalvetothe
manifold, even if it is several meters away. If
the downstream line behind the valve is ex-
tended by a conical expansion piece, con-
nect the control line in the expanded section
of the line. Weld the control line at the side
in the middle of the pipe, inclining at a ratio
of approximately 1:10 up to the compensa-
tion chamber.
Control line kit · A control line kit for tap-
ping pressure directly at the valve body is
available as an accessories part from
SAMSON.
Compensation chamber∙SeeTable1on
page7.Acompensationchamberisre-
quiredforliquidsabove150°Caswellas
for steam.
Fig.3: Examples of installation with steam 3.4 Connection above the middle of the ange
NOTICE
Always install the millibar pressure
regulator upright with the actuator
on top.
3.3 Control line connection below the
middle of the ange
3.2 Control line connection in manifold
3.1 Control line connection Min. pipe
diameter ½“
Additional
condensate
head
12 53 467
1235
6
8
1 Shut-off valve
2 Upstream pressure gauge
3 Strainer
4 Compensation chamber
5 Pressure reducing valve
6 Downstream pressure gauge
7 Shut-off valve
8 Steam trap

10 EB 2512 EN
Installation
The mounting position of the compensation
chamber is indicated by an adhesive label
on the chamber itself as well as by an arrow
and the word "top" stamped on the top of
the chamber.
Thismountingpositionmustbeadheredto;
otherwise the safe functioning of the pressure
reducing valve cannot be guaranteed.
Weld the line coming from the pressure tap-
ping point to the
3
/
8
“ pipe socket on the
chamber. Install the compensation chamber
at the highest point of the pipeline. Conse-
quently, the control line between compensa-
tion chamber and actuator must also be in-
stalled with a downward slope. In this case,
use a
3
/
8
“pipewithscrewttings.
If the control line connection is located below
themiddleofthevalveoutletange,arrange
the compensation chamber at the same level
astheoutletange(Fig.3.3).Inthiscase,
use a pipe which is at least ½“ in size for the
control line from the tapping point to the
compensation chamber.
If the control line is connected above the
middleofthevalveoutletange,installthe
compensation chamber at the same level as
the downstream pressure tapping point
(Fig.3.4).Theadditionalpressureofthe
condensate head must be compensated for
by adjusting the set point to a higher value.
Needle valve · If the regulator tends to hunt,
we recommend installing a needle valve at
thecontrollineconnection(16)inadditionto
the standard SAMSON screw joint with re-
striction.
4.4 Strainer (lter)
Install the strainer (e.g. SAMSON
Type2N/2NI)upstreamofthepressurere-
ducingvalve(seeFig.3).
−Selectastrainer(meshsize)suitablefor
the process medium.
−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.
−Remember to leave enough space to re-
movethelterelement.
4.5 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 periods
of time.
4.6 Pressure gauges
Install a pressure gauge both upstream and
downstream of the regulator to monitor the
pressures prevailing in the plant. Install the
pressure gauge on the downstream side be-
hind the downstream pressure tapping point
(not between the tapping point and the
valve).