Samson 2357-3 Service manual

Translation of original instructions
EB 2559 EN
Type2357-3 Pressure Build-up Regulator
Self-operated Pressure Regulators · Cryogenic
Edition April 2022
Type2357-3 with non-return unit at Port C
Ports A and B with solder nipple with ball-type bushing
Type2357-3 made of CrNi steel
(special version)

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
(aftersalesservic[email protected]om).
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 2559 EN

Contents
EB 2559 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 .................................................................................................2-1
2.2 Material identication number .....................................................................2-1
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...........................................................................5-3
5.3 Installation..................................................................................................5-3
5.3.1 Installing the regulator.................................................................................5-4
5.3.2 Cleaning the pipeline ..................................................................................5-4
5.4 Testing the regulator ....................................................................................5-4
5.4.1 Leak test.....................................................................................................5-5
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 ...................................................................................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 .......................................................................................8-2
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

Contents
EB 2559 EN
9.4 Replacing the set point spring ......................................................................9-4
9.5 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
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 Lubricant..................................................................................................15-2
15.3 Tools ........................................................................................................15-2
15.4 Spare parts ..............................................................................................15-2
15.5 Accessories ..............................................................................................15-2
15.6 After-sales service.....................................................................................15-2

EB 2559 EN 1-1
Safety instructions and measures
1 Safety instructions and measures
Intended use
The SAMSON Type2357-3 Regulator is a pressure regulator. The regulator is designed to
keep the pressure (either downstream pressure p2 or upstream pressure p1, depending on the
version) constant to the adjusted set point, especially in cryogenic plants. 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 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 regulators 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 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
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 2559 EN
Safety instructions and measures
Safety features
The Type2357-3 Regulator does not have any special safety features. When relieved of
pressure, the regulator is opened by the force of the set point springs.
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.
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, 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.

EB 2559 EN 1-3
Safety instructions and measures
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.
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 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 2559 EN
Safety instructions and measures
Referenced documentation
The following documents apply in addition to these mounting and operating instructions:
−Manuals
e.g. Oxygen manual uH01
−Data sheets for
e.g. Spare parts and accessories · Self-operated regulators for
cryogenic media uT2570
−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.
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 2559 EN 1-5
Safety instructions and measures
1.2 Notes on possible personal injury
WARNING
!
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 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 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.

1-6 EB 2559 EN
Safety instructions and measures
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 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 the equipment.
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 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.
SAMSON's After-sales Service can support you concerning lubricant, tightening torques
and tools approved by SAMSON.
Note

EB 2559 EN 2-1
Markings on the device
2 Markings on the device
2.1 Nameplate
1
2
3
4
5
6
A
B
C
7
1Valve type/date of manufacture
2Set point range/default set point setting
3 Material number/manufacturing index
4Serial number
5 Customer-specic details
6CE/EAC marking
7Marking for special version with reinforced
closing spring for use in the liquid phase
Fig.2-1: Nameplate of Type2357-3
2.2 Material identication
number
Specifying the material number, you can
contact us to nd out which material is used.
The conguration ID is specied on the
nameplate (3).
For more details on the nameplate, see sec-
tion2.1.

2-2 EB 2559 EN

EB 2559 EN 3-1
Design and principle of operation
3 Design and principle of oper-
ation
ÎSee Fig.3-1
The regulator consists of a valve with three
ports (A, B and C), a spring-loaded operat-
ing bellows (3) with set point adjuster (10)
and a tubular plug (2.2).
The process medium ows from port A to
port B in the pressure regulator used as a
build-up pressure regulator with safety func-
tion.
The regulator is open when relieved of pres-
sure. The pressure downstream of the regula-
tor is transmitted to the operating diaphragm
(3). The positioning force produced by this
pressure moves the pressure build-up plug
(2.1), which is rmly attached to the plug
sleeve, depending on the spring force adjust-
able at the set point adjuster (10). The regu-
lator closes as soon as the downstream pres-
sure has assumed the adjusted set point.
Functioning as a pressure build-up regulator,
the regulator also operates as a safety valve
for the pressure chamber upstream of port
A. When the pressure rises above the set
point by approx. 5bar, the positioning force
overcomes the force of the closing spring
(16), causing the pressure build-up plug
(2.1) to open and the pressure is relieved to
ports B and C.
Functioning as an excess pressure valve, the
medium ows from port B to C. The tubular
plug seals off the operating bellows when
there is no pressure drop across port B and
C. The pressure at port B acts on the operat-
ing bellows (3). The positioning force pro-
duced by this pressure opposes the adjust-
able spring force of the set point spring (8)
and opens the tubular plug (2.2) when the
pressure rises above the set point by approx.
0.5bar. The pressures are equalized and the
medium escapes through the inside of the tu-
bular plug over port C.
As an excess pressure valve, the regulator
can be optionally equipped with a non-re-
turn unit (12). It prevents the medium from
owing back to port C and allows mainte-
nance work to be performed on the regula-
tor without having to empty the tank rst.
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.

3-2 EB 2559 EN
Design and principle of operation
10
9
7
8
3
17
13
2.2
2.1
4.2
12
16
13
17
1
14
11
4.1
17
4
5
C
B
A
1Valve body
2.1 Pressure build-up plug
2.2 Tubular plug
3 Operating bellows
4 Coupling nut
4.1 Seal (body cover)
4.2 Seal (top section of body)
5 Screw plug
7Spring plate
8 Set point spring
9 Body cover
10 Set point adjuster
(hex socket, SW5)
11 Lock nut (SW17)
12 Non-return unit (accessories)
13 Filter
14 Body screws
16 Closing spring
17
Coupling nut for solder nipple
with ball-type bushing
(accessories)
Fig.3-1: Functional diagram of Type2357-3

EB 2559 EN 3-3
Design and principle of operation
3.1 Additional ttings
To consumer, ll-
ing station etc.
_
10
11
1
9
7
8
6.2
45
6.1 3
B
C
A
_
2
1Cryogenic tank
2Type 2357-3 Pressure Build-up
Regulator
3 Non-return unit
4Type2371-1 or Type2371-11
Pressure Reducing Valve
5Type2040 Temperature
Monitor
6.1
6.2 Shut-off valves
7 Pressure build-up vaporizer
8Final vaporizer
9Media 5/Media 7 Level Meter
10 Safety valve
11
Pressure protection by
Type2357-3 with special
accessories
Fig.3-2: Schematic drawing of Series 2357-3 Pressure Build-up Regulator with safety function for
cryogenic service

3-4 EB 2559 EN
Design and principle of operation
Shut-off valves
We recommend installing a shut-off valve (1)
in each of the inlets and outlets of the regula-
tor. The shut-off valves allow the plant to be
shut down for cleaning and maintenance,
and when the plant is not used for longer
periods of time.
Insulation
Regulators can be insulated to reduce cool-
ing losses.
Refer to the instructions in the 'Installation'
section.
The Type2357-3 Regulator is not a safety
valve. If necessary, a suitable overpressure
protection must be installed on site in the
plant section.
Note
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2559.
Process medium and scope of application
The regulator is designed to keep the pres-
sure constant to the adjusted set point, espe-
cially in cryogenic plants.
The regulator functions as a pressure build-
up regulator with safety function (direction of
ow from A to B, closing) or as an excess
pressure valve (direction of ow from B to C,
opening).
−Suitable for cryogenic gases and liquids
as well as other liquids, gases and va-
pors
−Min. temperature –196°C
−Max. temperature 200°C
−Set points from 2 to 40bar
−Valve size DN25/20
−Pressure rating PN40
Note

EB 2559 EN 3-5
Design and principle of operation
Noise emissions
SAMSON is unable to make general state-
ments about noise emissions. The noise emis-
sions depend on the regulator version, plant
facilities and process medium.
Risk of hearing loss or deafness due to loud
noise.
Wear hearing protection when working near
the regulator.
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.
Temperature range
Depending on how the regulator is cong-
ured, it can be used up to temperatures of
–196 to 200° (Table 3-1).
Conformity
The Type2357-3 Regulator bears both the
CE and EAC marks of conformity.
WARNING
!
WARNING
!
Dimensions and weights
Table 3-1 provides a summary of the
weights. The lengths, heights and other di-
mensions in the dimensional drawings are
shown on pages3-7 and 3-8.

3-6 EB 2559 EN
Design and principle of operation
Table 3-1: Technical data · All pressures in bar (gauge)
Type
2357-3
– Process medium in the gas
phase –
2357-3
– Special version in the liquid phase –
Pressure rating PN40
KVS coefcient 3.2
Set point range 2 to 10bar · 8 to 26bar · 25 to 40bar
Fail-safe action 5 bar above the set point 12 bar above the set point
Excess pressure
function 0.5 bar above the set point
Temperature range (–274°C)1) –196 to +200°C
Weight, approx. 3.5kg
Conformity ·
1) Version for liquid hydrogen
Table 3-2: Materials · Material numbers according to DIN EN
Type 2357-3
Body CC754S-GM (brass) 1.4404
Tubular plug 1.4301 1.4301
Plug 1.4301 ∙PTFE soft seal
Bellows 1.4571
Set point spring Stainless steel 1.4310
Body gasket PTFE
Connections
A, B M40x2 Welding ends 26.9x2
CM26x1.5 male thread
Non-return
unit M40x2 M26x1.5

EB 2559 EN 3-7
Design and principle of operation
Dimensions (in mm)
126
63
220
313
Ø 80
174
180
Type2357-3 · Standard version with solder nipple (accessories) and non-return unit (accessories)
Fig.3-3: Dimensions of the standard version

3-8 EB 2559 EN
Design and principle of operation
Dimensions (in mm)
Ø80
Ø28
M40 x
2
126
155
111
174
131
Weld seam performed on site
Type2357-3 · CrNi steel version with welding ends (accessories) and non-return unit (accessories)
Fig.3-4: Dimensions of the CrNi steel version