Samson 2357-1 Service manual

Translation of original instructions
EB 2557 EN
Type2357-1 Pressure Regulator · Type2357-2 Excess Pressure
Valve
Self-operated Pressure Regulators for special applications
Edition March 2021
Type2357-1 Pressure Regulator (pressure
build-up regulator or pressure reducing valve)
Type2357-2 Pressure Regulator
(excess pressure valve)

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.
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 2557 EN

Contents
EB 2557 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 Nameplate inscriptions................................................................................2-1
2.2 Materialidenticationnumber .....................................................................2-2
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............................................................4-1
4.4 Storing the regulator ...................................................................................4-2
5 Installation.................................................................................................5-1
5.1 Installation conditions..................................................................................5-1
5.2 Preparation for installation...........................................................................5-2
5.3 Installation activities ....................................................................................5-4
5.3.1 Installing the regulator.................................................................................5-5
5.3.2 Cleaning the pipeline ..................................................................................5-5
5.4 Testing the regulator ....................................................................................5-5
5.4.1 Leak test.....................................................................................................5-6
5.4.2 Pressure test................................................................................................5-6
6 Start-up .....................................................................................................6-1
6.1 Start-up and putting the device back into operation .......................................6-2
6.2 Starting up the plant when vapors and liquids are controlled..........................6-2
7 Operation..................................................................................................7-1
7.1 Adjusting the set point.................................................................................7-1
8 Malfunctions ..............................................................................................8-1
8.1 Troubleshooting ..........................................................................................8-1
8.1.1 Type2357-1aspressurereducingvalve.......................................................8-1
8.1.2 Type2357-1aspressurebuild-upregulator..................................................8-2
8.1.3 Type2357-2asexcesspressurevalve...........................................................8-3
8.2 Emergency action .......................................................................................8-4

Contents
EB 2557 EN
9 Servicing....................................................................................................9-1
9.1 Preparing the valve for service work.............................................................9-4
9.2 Installing the regulator after service work ......................................................9-4
9.3 Service work...............................................................................................9-4
9.4 Changing the set point range.......................................................................9-5
9.5 Cleaningandexchangingtheseatandplug .................................................9-5
9.6 Ordering spare parts and operating supplies ................................................9-6
10 Decommissioning .....................................................................................10-1
11 Removal ..................................................................................................11-1
11.1 Removing the regulator from the pipeline....................................................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 Tools ........................................................................................................15-1
15.3 Lubricant..................................................................................................15-1
15.4 Spare parts and accessories ......................................................................15-2
15.5 After-sales service.....................................................................................15-2

EB 2557 EN 1-1
Safety instructions and measures
1 Safety instructions and measures
Intended use
TheSAMSONType2357-1andType2357-2Regulatorsarepressureregulators.
The self-operated regulators are used as a pressure reducing valve/pressure build-up regula-
tor(Type2357-1)orasanexcesspressurevalve(Type2357-2).Cryogenicgasesandliq-
uids as well as other liquids, gases and vapors in industrial plants can be controlled by the
regulators.
Theregulatorsaredesignedtooperateunderexactlydenedconditions(e.g.operatingpres-
sure, 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 regulator in other applications or con-
ditions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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
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:
ÎProtective clothing, safety gloves and eye protection in applications with hot, cold and/or
corrosive media
ÎWear hearing protection when working near the valve
ÎCheck with the plant operator for details on further protective equipment.

1-2 EB 2557 EN
Safety instructions and measures
Qualications of operating personnel
The regulators must be mounted, started up, serviced and repaired by fully trained and qual-
i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.
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regulators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,warning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 cover the standard version of the devices and the
standard mounting parts. Components that differ to those described in this document can be
added or removed. Refer to the mounting and operating instructions of the components not
covered in this document for the safety instructions and measures that need to be observed.
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.

EB 2557 EN 1-3
Safety instructions and measures
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.
Safety features
The regulators do not have any special safety features. When relieved of pressure, the
Type2357-1Regulatorisopenedbytheforceoftheinternalvalvespringsandthe
Type2357-2Regulatorisclosedbytheforceoftheinternalvalve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.
Referenced standards, directives 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'Certicates'section.
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0165-1).
Referenced documentation
The following documents apply in addition to these mounting and operating instructions:
−Datasheetsfor
e.g. Spare parts and accessories · Self-operated regulators for cryogenic
media uT2570
−Manuals
e.g. Oxygen manual uH01

1-4 EB 2557 EN
Safety instructions and measures
−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 the regulator.
Regulators and pipelines are pressure equipment. Impermissible pressure or improper
opening of the regulator 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affected
as well as the regulator.
ÎDraintheprocessmediumfromalltheplantsectionsaffectedaswellastheregula-
tor.
Risk of injury due to incorrect handling of oxygen or cryogenic gases in applica-
tions.
Theregulatorcanbeusedforoxygenserviceorapplicationswithcryogenicgases.
Oxygenisahazardoussubstance,whichreactsquickly,leadingtocombustionand
explosions.Contactwithcryogenicgasescausesseverefrostbiteandcoldburns(cryo-
genicburns).Operatingpersonnelmustbetrainedfortheseapplications.Unqualied
operatingpersonnelexposethemselvesandotherstoanincreasedriskofinjury.
ÎOperatingpersonnelmustbesufcientlytrainedandbemadeawareofthehaz-
ardsinapplicationsinvolvingoxygenorcryogenicgases.
ÎInstructionsandinformationonhowtosafelyhandledevicesforoxygenservice
can be found in the Manual uH01.

EB 2557 EN 1-5
Safety instructions and measures
1.2 Notes on possible personal injury
WARNING
!
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.
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 uwww.samsongroup.com/reach-en.
html
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 affected and the
regulator.
ÎWear protective clothing, safety gloves and eye protection.
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.

1-6 EB 2557 EN
Safety instructions and measures
1.3 Notes on possible property damage
NOTICE
!
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.
Risk of regulator damage due to incorrectly attached slings.
ÎDonotattachload-bearingslingstotheregulator.
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 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.

EB 2557 EN 1-7
Safety instructions and measures
1.3 Notes on possible property damage
NOTICE
!
Incorrect control due to the formation of ice on the regulator.
Mediumtemperaturesbelow0°Cmaycauseicetoformontheregulator,depending
on the air humidity. This may affect, in particular, the functioning of the internal set
point springs.
ÎPrevent the formation of ice by taking appropriate precautions (e.g. enclosure,
trace heater etc.). The plant operator is responsible for selecting and implementing
appropriate precautions. See the 'Installation' section.
ÎIn the event that the formation of ice restricts the movement of the springs, we rec-
ommend using a heat gun to melt the ice.
SAMSON's After-sales Service can support you concerning lubricant, tightening torques
and tools approved by SAMSON.
Note

1-8 EB 2557 EN
Safety instructions and measures

EB 2557 EN 2-1
Markings on the device
2 Markings on the device
2.1 Nameplate inscriptions
Nameplate on the front of the body Back of the body
1
2
3
4
5
1 Type designation and year of manufacture
2 Set point range/default set point setting
3Materialnumberanddeviceindex
4 Serial number
5Customer-specicdetails
Fig.2-1: Valve nameplate

2-2 EB 2557 EN
Markings on the device
2.2 Material identication
number
Specifying the material number, you can
contactustondoutwhichmaterialisused.
Thematerialnumberisspeciedonthe
nameplate (3).
For more details on the nameplate, see sec-
tion2.1.

EB 2557 EN 3-1
Design and principle of operation
3 Design and principle of oper-
ation
ÎSeeFig.3-1
Type2357-1
ÎPressure build-up regulator
DirectionofowfromportBtoportA.The
pressure upstream of the valve (port B) is
transmitted to the operating diaphragm. The
valve closes when the upstream pressure in-
creases and opens when the upstream pres-
sure drops.
The pressure build-up regulator operates as
a safety valve and relieves the pressure
chamber upstream of the inlet of pressure
whenthepressureexceedsthesetpointby
5bar.Afterovercomingthespringforceof
the top springs (16), the valve opens to
equalizethepressures.
ÎPressure reducing valve
DirectionofowfromportAtoportB.The
valve is open when no pressure is applied.
The pressure downstream of the valve (port
B) is transmitted to the operating diaphragm
(3). The positioning force produced moves
the valve plug (2.1) depending on the spring
force adjustable at the set point adjuster
(10). The valve closes when the pressure
downstream of the valve (port B) rises.
Type2357-2
ÎExcesspressurevalve
DirectionofowalwaysfromportAtoport
B. The valve is closed when no pressure is
applied. The pressure at port A is transmitted
internally to the operating diaphragm (3).
The positioning force produced opposes the
adjustable spring force. The valve opens
when the pressure increases until the set
point is reached.
The regulator can be optionally equipped
with a non-return unit (12), which prevents
themediumfromowingbackthroughthe
valve.
EC type examination
AnECtypeexaminationaccordingtothe
PressureEquipmentDirective97/23/EC,
Module B has been performed on the regu-
lators(PN50version).

3-2 EB 2557 EN
Design and principle of operation
4.2
1
2.1
3
A
16
13
17
13
4.1
5
6
7
8
9
7
10
11
17
B
Type2357-1 1
3
5
6
7
8
9
10
11
12
13
4.
1
7
17
B
A
Type2357-2
1 Top section of the body
2.1 Plug
3 Operating diaphragm
4.1 Gasket(bottomsection
of the body)
4.2 Gasket(topsectionof
the body)
5Diaphragmplate
6 Ball
7 Spring plate
8 Set point springs
9Bottom section of the
body
10 Set point adjuster
11 Lock nut
12 Non-return unit
(optional)
13 Filter
16 Plug spring
17 Solder nipple with ball-
type bushing (optional)
Fig.3-1: Functional drawings

EB 2557 EN 3-3
Design and principle of operation
3.1 Additional ttings
ÎSeeFig.3-2
Insulation
Regulators can be insulated to reduce heat
energy transfer.
Refer to the instructions in the 'Installation'
section.
Shut-off valves
We recommend installing shut-off valves
(6.1, 6.2, 12). Their installation ensures the
plant does not be completely shut down for
service and repair work on the regulator or
whentheplantisnotoperatedforextended
periods.
13
3
6.2
10
1
9
7
8
6.1 11 2
BA
412
5
TR
+
_
_
1 Cryogenic tank
2Type 2357-1 Pressure Build-up
Regulator
3Type2357-2ExcessPressure
Valve(economizer)
4Type2357-1PressureReducing
Valve
5Type2040Temperature
Monitor
6.1 Shut-off valve
6.2 Shut-off valve
7Pressurebuild-upvaporizer
8Finalvaporizer
9Media7/Media5LevelMeter
10 Safety valve
11 Strainer
12 Shut-off valve
13
Pressure protection by
Type2357-3asexcesspressure
valve with special accessories
Fig.3-2: Series2357 Pressure Regulator for cryogenic service, schematic drawing

3-4 EB 2557 EN
Design and principle of operation
3.2 Technical data
The regulator nameplate provides informa-
tion on the regulator version (see the 'Mark-
ings on the device' section).
More information is available in Data Sheet
uT2557.
Process medium and scope of application
TheType2357-1andType2357-2Pressure
Regulators are designed to keep the pressure
constant to an adjusted set point, especially
in cryogenic plants.
−Pressure regulators for cryogenic gases
and liquids as well as other liquids,
gases and vapors
−Temperature range from –196 to
+200°C
−Set points from 0.2 to 40bar
−ValvesizeG¾
−Pressure rating PN40 and 50
Type2357-1 (pressure reducing valve):
The regulator closes when the downstream
pressure rises
Type2357-1 (pressure build-up regulator):
The regulator opens when the upstream
pressure drops
Type2357-2 Excess Pressure Valve:
The regulator opens when the upstream
pressure rises.
Note
Conformity
TheType2357-1andType2357-2Regula-
tors bear the CE mark of conformity.
EC type examination
AnECtypeexaminationaccordingtothe
PressureEquipmentDirective97/23/EC,
Module B has been performed on the regu-
lators(PN50version).
Serial number
The devices are marked with a serial number
onthenameplate.Detailsonthenameplate
are listed in uEB2557.
Noise emissions
SAMSON is unable to make general state-
ments about noise emissions. The noise emis-
sions depend on the regulator version, plant
facilities, process medium and operating
conditions.
Dimensions and weights
Table 3-4 provides a summary of the dimen-
sions and weights. The lengths and heights
in the dimensional drawings are shown on
page3-6.

EB 2557 EN 3-5
Design and principle of operation
Table 3-1: Technical data · All pressures in bar (gauge)
Type... Regulator 2357-1 2357-2
KVScoefcient 0.25 0.8 1.25 0.4
Set point ranges 1) in bar 1to25·10to36 1to8·5to25·8to40 1to25·10to36
Pressure rating PN 40 PN502) PN 40
Max.perm.operatingpressure 50bar
Max.permissible
differential pressure
∆p
Type2357-1 Gases:30bar·Liquids:6bar
Type2357-2 3bar(>3baronlywithspecialaccessories;KVScoefcientreducedto0.02)
Safety function for Type 2357-1 5 bar above the set point
Temperature range –196to+200°C
Conformity
1) Further set point ranges on request
2) Foroxygenpmax=40bar
Table 3-2: Materials · Material numbers according to DIN EN
Type... Regulator 2357-1 2357-2
Body and cover CC754S-GM(brass) 1)
Plug CW602N (brass) with PTFE soft seal –
Operating diaphragm CuBe
Set point springs Stainless steel 1.4310
Body gasket PTFE
1) PN40:CW617N(brass)
Table 3-3: Valve versions and end connections
Regulators Design Version Connections
Input Output
Type2357-1
Pressure build-up
regulator/pressure
reducing valve
Globevalve G¾A
conical joint
Type2357-2 Excesspressurevalve Angle valve G¾A
conical joint
G¾
female thread

3-6 EB 2557 EN
Design and principle of operation
Table 3-4: Dimensions in mm and weights in kg
Type... Regulator 2357-1 2357-2
PN 40 PN50 PN 40 PN50
Length L 110mm 55mm
Length L1 150mm 75mm
Height H 95mm 140mm 95mm 140mm
Height H2 35mm 51mm 40mm
Height H3 – 25mm
Pipe Ø d 15or16mm
Connection R G¾
Weight, approx. 0.9kg 2.0kg 0.6kg 1.7kg
Dimensional drawings
L1
L
H2
H
Ød
R
R
L
L1
H
Ød
H3
H2
R
Type2357-1PressureRegulatorwithsoldernipple
(accessories)
Type 2357-2 Pressure Regulator with solder nipple and
non-return unit (accessories)
Fig.3-3: Dimensions