Samson 2357-3 Service manual

Translation of original instructions
EB 2559 EN
Type2357-3 with non-return unit at port C·Ports A and B with soldering
nipple with ball-type bushing
Type2357-3 Pressure Build-up Regulator
Self-operated Pressure Regulators
Edition March 2019

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
([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.
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 2559 EN

Contents
EB 2559 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 ...................................................................9
1.3 Notes on possible property damage ..............................................................10
2 Markings on the device ...............................................................................12
2.1 Nameplate ..................................................................................................12
2.2 Material number ..........................................................................................13
2.2.1 Type2357-3 Regulator .................................................................................13
3 Designandprincipleofoperation ................................................................14
3.1 Technical data .............................................................................................16
4 Measuresforpreparationbeforeinstallation ................................................20
4.1 Unpacking ..................................................................................................20
4.2 Transport, lifting and storage ........................................................................20
4.2.1 Storage .......................................................................................................21
5 Mounting position .......................................................................................21
5.1 Preparation for installation ............................................................................21
5.2 Checking the installation conditions ...............................................................22
5.2.1 Mounting position ........................................................................................22
5.2.2 Shut-off valves .............................................................................................22
6 Start-upandoperation ................................................................................24
6.1 Start-up .......................................................................................................24
6.2 Installing the regulator ..................................................................................24
6.3 Operation ...................................................................................................25
6.4 Starting up the plant .....................................................................................25
6.5 Adjusting the set point ..................................................................................26
7 Servicing.....................................................................................................27
7.1 Replacing the set point springs ......................................................................29
7.2 Tightening torques ........................................................................................30
7.3 Lubricants and sealants ................................................................................30
7.4 Prepare the regulator for return shipment .......................................................31
7.5 Ordering spare parts and operating supplies .................................................31
8 Malfunctions ...............................................................................................32
9 Decommissioningandremoval ....................................................................33
9.1 Decommissioning .........................................................................................33
9.2 Disposal ......................................................................................................33

Contents
4 EB 2559 EN
10 Annex.........................................................................................................34
10.1 After-sales service ........................................................................................34
10.2 Spare parts and accessories .........................................................................34
10.3 Certicates ..................................................................................................34

EB 2559 EN 5
Safety instructions and safety measures
1 Safety instructions and safety measures
Intended use
The SAMSON Type2357-3 Pressure 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 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 2559 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
hazard statements, warning and caution notes in these mounting and operating instructions,
especially 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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.
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 2559 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 Annex 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:
−Manuals
Oxygenmanual uH01
−Data sheets
For example: Sparepartsandaccessories·Self-operated
regulatorsforcryogenicmedia uT2570
−Mounting and operating instructions as well as data sheets for additional components
(e.g. shut-off valves, pressure gauges etc.).

8 EB 2559 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.

EB 2559 EN 9
Safety instructions and safety 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http://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 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.

10 EB 2559 EN
Safety instructions and safety 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 actuator housing.
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7.2).

EB 2559 EN 11
Safety instructions and safety measures
1.3 Notesonpossiblepropertydamage
NOTICE
!
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

12 EB 2559 EN
Markings on the device
2 Markings on the device
2.1 Nameplate
1
2
3
4
5
6
A
B
C
1Valve type/
Date of manufacture
2Set point range/
Default setting of set point
3Conguration ID/
Manufacturing index
4Serial number
5 Customer-specic details
6CE marking/
EAC marking
Fig.1: Nameplate of Type2357-3

EB 2559 EN 13
Markings on the device
2.2 Materialnumber
2.2.1 Type2357-3Regulator
Specifying the conguration ID, you can con-
tact us to nd out which material is used. The
conguration ID is specied on the name-
plate (3). For more details on the nameplate,
see section2.1.

14 EB 2559 EN
Designandprincipleofoperation
3 Designandprincipleofoper-
ation
See Fig.2.
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 Type2357-3 Pressure Regulator
used as a build-up pressure regulator with
safety function.
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.

EB 2559 EN 15
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
Type2357-3
1Valve body
2.1 Pressure build-up plug
2.2 Tubular plug
3 Operating bellows
4Coupling nut
4.1 Seal (body cover)
4.2 Seal (top section of body)
5 Screw plug
7 Spring plate
8Set point spring
9Housing cover
10 Set point adjuster
(hexagon 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 soldering
nipple with ball-type bushing
(accessories)
Fig.2: Design and principle of operation

16 EB 2559 EN
Designandprincipleofoperation
3.1 Technicaldata
The regulator's nameplate contains informa-
tion on the regulator version (see sec-
tion2.1).
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
−Nominal size DN25/20
−Pressure rating PN40
Temperature range
Depending on how the regulator is cong-
ured, it can be used up to temperatures of
–196 to 200° (Table1).
Noise emission
SAMSON is unable to make general state-
ments about noise emission as it depends on
the valve 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.
Dimensionsandweights
Table1 provides a summary of the weights.
The lengths and heights are shown in the di-
mensional drawings on page19 and
18.
WARNING
!
WARNING
!

EB 2559 EN 17
Designandprincipleofoperation
Table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
Safety function 5 bar above the set point 12 bar above the set point
Excess pressure
function 0.5 bar above the set point
Temperature range –196 to +200°C
Weight, approx. 3.5kg
Compliance ·
Table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
Connec-
tions
A, B M40x2 Welding ends 26.9x2
CM26x1.5 male thread
Non-return unit M40x2 M26x1.5

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

EB 2559 EN 19
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: Dimensions

20 EB 2559 EN
Measuresforpreparationbeforeinstallation
4 Measures for preparation
beforeinstallation
After receiving the shipment, proceed as fol-
lows:
1. Check the scope of delivery. Compare
the shipment received with the delivery
note.
2. Check the shipment for transportation
damage. Report any damage to
SAMSON and the forwarding agent
(refer to delivery note).
In the delivered state, the regulators are
packed to be free of oil and grease for oxy-
gen service.
Do not open or remove the packaging until
immediately before installation.
4.1 Unpacking
In the delivered state, the regulators are
packed to be free of oil and grease for oxy-
gen service.
Do not remove the packaging until immedi-
ately before installation.
Note
NOTICE
!
Before installing the regulator, proceed as
follows:
1. Remove the packaging from the control-
ler.
2. Dispose of the packaging in accordance
with the valid regulations.
4.2 Transport,liftingand
storage
Due to the low service weight, lifting equip-
ment is not required to lift and transport the
regulator (e.g. to install it into the pipeline).
Transport instructions
−Protect the device against external inu-
ences (e.g. impact).
−Do not open or remove the packaging
until immediately before installation.
−Protect the device against moisture and
dirt.
−Observe the permissible ambient tem-
peratures (see sectionTable1).