Samson 2357-11 Service manual

Mounting and
Operating Instructions
EB 2560 EN
Edition August 2014
Type2357-11 Pressure Build-up Regulator/Type 2357-21 Excess Pressure Valve
Self-operated Pressure Regulators
Type 2357-11 Pressure Build-up Regulator
Type 2357-21 Excess Pressure 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 2560 EN

Contents
EB 2560 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....................................................................................................8
4.1 Mounting position..........................................................................................8
4.2 Shut-off valve.................................................................................................8
5 Operation.....................................................................................................8
5.1 Start-up.........................................................................................................8
5.2 Set point adjustment.......................................................................................8
5.2.1 Changing the set point range..........................................................................9
5.3 Decommissioning.........................................................................................10
6 Maintenance ...............................................................................................10
6.1 Exchanging the seat and plug.......................................................................10
6.2 Exchanging the non-return unit .....................................................................11
7 Customer service.........................................................................................12
8 Nameplate..................................................................................................12
9 Dimensions and weights..............................................................................13
10 Technical data.............................................................................................14

4 EB 2560 EN
General safety instructions
1 General safety instructions
−The regulators are 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 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 pressure regulator by the process
medium, operating pressure or by moving parts are to be prevented by tak-
ing appropriate precautions.
−Proper transport, storage, installation, operation and maintenance are as-
sumed.

EB 2560 EN 5
Process medium and scope of application
2 Process medium and scope of application
Pressure regulators for cryogenic gases and liquids as well as other liquids, gases and va-
pors. Operating pressures up to 63bar, with set points from 1 to 40bar. Temperature range
from –200 to +200°C. Oxygen clean according to international standards and guidelines.
The regulators are designed to keep the pressure constant to the adjusted set point, especial-
ly in cryogenic plants.
WARNING!
Risk of injury and property damage due to high pressure in the plant!
A suitable overpressure protection must be installed on site in the plant section.
2.1 Transportation and storage
The regulators must be carefully handled, transported and stored. Protect the regulators
against adverse inuences, such as dust, dirt or moisture before they are installed.
In the delivered state, the pressure regulators are packed to be free of oil and grease for oxy-
gen service. To avoid contamination, do not open the packaging until immediately before in-
stallation.

6 EB 2560 EN
Design and principle of operation
3 Design and principle of op-
eration
See Fig. 1 on page7.
Ports A and B are marked on the valve body.
Type 2357-11 Pressure Build-up Regulator
Functioning as a Type 2357-11 Pressure
Build-up Regulator (Fig. 1) with direction of
ow from port B to port A, the pressure up-
stream of the valve (port B) is transmitted to
the operating diaphragm. The valve closes
when the upstream pressure increases and
opens when the upstream pressure decreas-
es.
The pressure build-up regulator operates
as a safety valve and relieves the pressure
chamber of pressure when the pressure ex-
ceeds the set point by 5bar. After overcom-
ing the force of the top plug spring (16), the
valve opens to equalize the pressures.
The valve is open when no pressure is ap-
plied. The pressure upstream of the valve
(port B) is transmitted to the operating dia-
phragm (3). The positioning force produced
moves the valve plug (2) depending on the
spring force adjustable at the set point ad-
juster (10). The valve closes when the pres-
sure upstream of the valve (port B) increases.
Type 2357-11 Pressure Reducing Valve
The process medium ows from port A to
port B when the Type2357-11 Pressure Reg-
ulator is used as a pressure reducing valve.
The valve is open when no pressure is ap-
plied. The pressure downstream of the valve
(port B) is transmitted to the operating dia-
phragm (3). The positioning force produced
moves the valve plug (2.1) depending on the
spring force adjustable at the set point ad-
juster (10). The valve closes when the pres-
sure downstream of the valve (port B) rises.
Type 2357-21 Excess Pressure Valve
The medium ows through the Type 2357-21
Excess Pressure Valve (Fig. 3) from port B to
port A. The valve is closed when no pressure
is applied. The pressure at port B is trans-
mitted 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 integrated non-return
unit prevents the medium from owing back.
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.

EB 2560 EN 7
Design and principle of operation
Fig. 1: Functional diagram
Direction of ow
Pressure build-up regulator
Pressure reducing valve
1 Valve body
2.1 Plug
3 Operating diaphragm
4.1 Gasket (bottom section of the body)
5 Diaphragm plate
6 Ball
7 Spring plate
8 Set point springs
9 Spring housing (bottom section of the
body)
10 Set point adjuster (hexagon socket,
5mm)
11 Lock nut (17mm)
12 Integrated non-return unit
14 Body screws
15 Seat
16 Plug spring
Type2357-11
Type2357-21
16
2.1
B
1
15
5
6
7
8
7
9
11
10
3
4.1
A
4.1
3
1
14
12
5
6
7
8
7
9
11
10
BA

8 EB 2560 EN
Installation
4 Installation
In the delivered state, the regulators are
packed to be free of oil and grease for oxy-
gen service.
WARNING!
Use of oil and grease in oxygen at-
mospheres!
Risk of explosion!
Make sure that the regulator is abso-
lutely clean and free of oil and grease
on installing it.
Flush and clean the pipeline thoroughly be-
fore installing the regulator.
−Make sure the regulator is installed free
of stress.
−Install a strainer upstream of the regu-
lator.
Otherwise, impurities in the pipeline
may impair the proper functioning of the
valve, above all the tight shut-off.
4.1 Mounting position
Install the pressure regulator with
the actuator housing suspended
downward in horizontal pipelines.
Observe the ow direction.
Type 2357-11 Pressure Build-up Regulator
with safety function
−Direction of ow from port Bto port A
Type 2357-11 Pressure Reducing Valve
−Direction of ow from port Ato port B
Type 2357-21 Excess Pressure Valve with
with non-return unit
A
B
−Direction of ow from port Bto port A
The ports are marked.
Required spare parts and accessories are
listed in Data Sheet uT2570EN.
4.2 Shut-off valve
We recommend installing a hand-operat-
ed shut-off valve both upstream and down-
stream of the regulator. This allows the plant
to be shut down for cleaning and mainte-
nance, and when the plant is not used for
longer periods of time.
Install a pressure gauge at a suitable point to
monitor the pressures prevailing in the plant.
5 Operation
See Fig. 1 on page7.
5.1 Start-up
First start up the regulator after mounting all
parts.
5.2 Set point adjustment
Every pressure regulator is delivered with the
set point listed in Table 1 already adjusted.
Turn the set point adjuster (10) using Al-
len key (size 5mm) to change the default set
point.
Provided a pressure gauge has been in-
stalled at a suitable point in the plant, the
required set point can be directly adjusted

EB 2560 EN 9
Operation
while monitoring the pressure reading at the
gauge.
When a pressure gauge is not installed, ad-
just the set point using the adjustment dia-
gram Fig. 2.
To increase the set point, turn the set point
adjuster into the body () and out of the
body () to reduce it.
NOTICE!
Set point adjuster screwed too tight!
The regulator is blocked and the me-
dium ow through it is restricted. Pres-
sure regulation is no longer possible!
Only screw the set point adjuster up
to the point where the spring tension
can still be felt!
How to proceed:
1. Loosen the lock nut (11, size 17mm) to
allow the set point adjuster to move free-
ly.
2. Determine the difference between the
xed set point (Table 1) and the required
set point. Turn the set point adjuster (10)
the required amount of turns as specied
in Fig. 2 on page10.
Based on the default setting, any subsequent
change to the set point can be also be made
by determining the required number of turns
using the specications listed in Table 1.
3. Lock the setting with the lock nut (11).
5.2.1 Changing the set point
range
The default set point ranges can be adapt-
ed to your specic requirements. Contact
SAMSON (see section7) for further details.
Table 1: Set point adjustment (default)
Set point range 1 to 8bar 5 to 25bar 8 to 40bar
Set point adjusted at the factory
(approx.)
2357-11 3bar 12bar 25bar
2357-21 4bar 13bar 26bar
Set point change per turn 1bar 2.5bar 3.5bar

10 EB 2560 EN
Maintenance
012345678910 11 12 13 14
0
5
10
15
20
25
30
35
40
1...8 bar
5...25 bar
8...40 bar
Fig. 2: Adjustment diagram
5.3 Decommissioning
Close rst the shut-off valve on the upstream
side of the valve and then on the down-
stream side of the valve.
Turns of the set point adjuster
: to increase the set point
: to reduce the set point
Set point
[bar] 6 Maintenance
The regulators do not require any mainte-
nance. Nevertheless, they are subject to nat-
ural wear, particularly at the seat, plug and
operating diaphragm.
Depending on the operating conditions,
check the regulator at regular intervals to
avoid possible malfunctions.
WARNING!
Process medium can escape uncon-
trolled on dismantling the regulator.
Risk of cold burns!
Allow the regulator to defrost before
depressurizing and draining it and re-
move it from the pipeline.
If faults or malfunctions cannot be remedied,
contact SAMSON (see section7).
6.1 Exchanging the seat and
plug
See Fig. 1 on page7.
1. Loosen the lock nut (11) and turn the set
point adjuster (10) counterclockwise to
fully relieve the internal set point springs
(8).
2. Unscrew the body screws (14) using an
open-end wrench (size 19mm). Lift off
the valve body (1).
3. Unscrew the seat (15) using a seat
wrench (size 30mm socket). Remove the
plug (2.1).
Set point ranges

EB 2560 EN 11
Maintenance
4. Insert the plug spring (16) into the new
plug (Type2357-11 only). Tighten the
seat using a seat wrench and a tight-
ening torque of 20Nm. Use a suitable
high-performance lubricant (e.g. Gleitmo
595, SAMSON order no. 8150-0116).
5. Check the PTFE gasket (4.1) and replace
it, if necessary.
6. Carefully mount the valve body (1) and
fasten it onto the bottom section of the
body (9) (tightening torque 25Nm).
6.2 Exchanging the non-return
unit
See Fig. 1 on page7.
1. Loosen the lock nut (11) and turn the set
point adjuster (10) counterclockwise to
fully relieve the internal set point springs
(8).
2. Unscrew the body screws (14) using an
open-end wrench (size 19mm). Lift off
the valve body (1).
3. Unscrew the integrated non-return unit
(12) using a seat wrench (30mm size
socket) and lift off the valve body (1).
4. Check the ball and seating surface. If
necessary, replace the entire non-return
unit. Mount the non-return unit using a
seat wrench (tightening torque 20Nm).
Use a suitable high-performance lubri-
cant (e.g. Gleitmo 595, SAMSON order
no. 8150-0116).
5. Check the PTFE gasket (4.1) and replace
it, if necessary.
6. Carefully mount the valve body (1) and
fasten it onto the spring housing (9) us-
ing the body screws (14) (tightening
torque 25Nm).

12 EB 2560 EN
Customer service
Details on lower section of body
1 Set point range/date of manufacture
2 Type designation with index
3 Customer-specic details
CE compliance
7 Customer service
If malfunctions or defects occur, contact the SAMSON After-sales Service Department for
support.
The addresses of SAMSON AG, its subsidiaries, representatives and service facilities world-
wide can be found on the SAMSON website (uwww.samson.de), in all SAMSON product
catalogs or on the back of these Mounting and Operating Instructions.
Please send your inquiries to: ser[email protected]
To assist diagnosis and in case of an unclear mounting situation, specify the following details
(see section8):
−Type designation and KVS coefcient
−Model number with index
−Upstream and downstream pressure
−Temperature and process medium
−Min. and max. ow rate
−Is a strainer installed?
−Installation drawing showing the exact location of the regulator and all the additionally
installed components (shut-off valves, pressure gauge, etc.)
8 Nameplate
Fig. 3: Nameplate details
1
2
3

EB 2560 EN 13
Dimensions and weights
9 Dimensions and weights
100
140
140
51
G ¾ A
Type 2357-11 Pressure Regulator/Type 2357-21 Excess Pressure Valve with welding ends
(accessories)
Weight: approx. 4kg
All dimensions in mm
Fig. 4: Dimensions and weights

14 EB 2560 EN
Technical data
10 Technical data
Type 2357-11 2357-21
KVS coefcient 0.8 1.25
Set point ranges 1) in bar 1 to 8 · 5 to 25 · 8 to 40
Max. perm.operating pressure pmax 63bar 2)
Safety function for Type 2357-11 5 bar above the set point
Max. perm. differential pressure
∆pmax
Types 2357-11 Pressure Reducing Valves: Gases 30 bar
Liquids 6 bar
Type 2357-21 Excess Pressure Valve: 3bar (> 3bar only with
special accessories)
Temperature range –200 to +200 °C
1) Further set point ranges on request
2) For oxygen pmax = 40bar

EB 2560 EN 15

SAMSON AG · MESS- UND REGELTECHNIK
Weismüllerstraße 3 · 60314 Frankfurt am Main, Germany
Phone: [phone] · Fax: [phone]
[email protected] · www.samson.de EB 2560 EN
2014-09-16 · English