Samson 41-23 Series Service manual

Translation of original instructions
EB 2512 EN
Type41-23 Universal Pressure Reducing Valve
Self-operated Pressure Regulators
Edition June 2020

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
Department (aftersalesser[email protected]).
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.samson.de > 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 2512 EN

Contents
EB 2512 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
1.4 Warnings on the regulator...........................................................................1-9
2 Markings on the device ..............................................................................2-1
2.1 Nameplates................................................................................................2-1
2.2 Locations of the nameplate ..........................................................................2-2
2.3 Material numbers........................................................................................2-2
2.3.1 Type 2412 Valve.........................................................................................2-2
2.3.2 Type2413Actuator ....................................................................................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 valve and actuator ....................................4-1
4.3 Transporting and lifting the regulator............................................................4-2
4.3.1 Transporting the regulator............................................................................4-2
4.3.2 Lifting the regulator .....................................................................................4-3
4.4 Storing the valve.........................................................................................4-4
5 Installation.................................................................................................5-1
5.1 Installation conditions..................................................................................5-1
5.2 Preparation for installation...........................................................................5-4
5.3 Assembly ...................................................................................................5-6
5.3.1 Installing the regulator.................................................................................5-6
5.3.2 Cleaning the pipeline ..................................................................................5-7
5.4 Testing the regulator....................................................................................5-8
5.4.1 Leak test.....................................................................................................5-9
5.4.2 Pressure test................................................................................................5-9
5.5 Insulation .................................................................................................5-10
6 Start-up .....................................................................................................6-1

Contents
EB 2512 EN
6.1 Starting up the plant....................................................................................6-2
6.1.1 Regulation of liquids....................................................................................6-2
6.1.2 Regulation of steam.....................................................................................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 .......................................................................................8-3
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
9.3.1 Replacing the actuator.................................................................................9-5
9.3.2 Replacing the set point springs.....................................................................9-6
9.3.3 Replacing the seat and plug.........................................................................9-7
9.3.4 Replacing the operating diaphragm .............................................................9-7
9.4 Ordering spare parts and operating supplies ................................................9-8
10 Decommissioning .....................................................................................10-1
11 Removal ..................................................................................................11-1
11.1 Removing the valve 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..................................................................................................15-1
15.3 Tools ........................................................................................................15-1
15.4 Accessories ..............................................................................................15-1
15.5 Spare parts ..............................................................................................15-2
15.6 After-sales service.....................................................................................15-4

EB 2512 EN 1-1
Safety instructions and measures
1 Safety instructions and measures
Intended use
TheSAMSONType41-23Regulatorisapressureregulator.ItconsistsofaType2412Valve
andaType2413Actuator.Thevalveandactuator(exceptfortestedregulators)aredeliv-
ered separately and must be assembled together according to these instructions.
The self-operated regulator is used to control the downstream pressure p2in the pipeline to
the adjusted set point. 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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 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.

1-2 EB 2512 EN
Safety instructions and measures
Personal protective equipment
Werecommendcheckingthehazardsposedbytheprocessmediumbeingused(e.g.
uGESTIS(CLP)hazardoussubstancedatabase).Dependingontheprocessmediumand/or
the activity, the protective equipment required includes:
−Protectiveclothing,safetyglovesandeyeprotectioninapplicationswithhot,coldand/or
corrosive media
−Wear hearing protection when working near the valve
−Hard hat
−Safety harness when working at height
−Safety footwear, ESD (electrostatic discharge) footwear, if necessary
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haz-
ard 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substancedatabase).
ÎObservesafetymeasuresforhandlingthedeviceaswellasrepreventionandexplosion
protection measures.
Safety features
TheType41-23Regulatordoesnothaveanyspecialsafetyfeatures.Whenrelievedofpres-
sure, the regulator is opened by the force of the set point springs.

EB 2512 EN 1-3
Safety instructions and measures
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.
Theoperatoris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 processes 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, 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'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
Directive 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).

1-4 EB 2512 EN
Safety instructions and measures
Referenced documentation
The following documents apply in addition to these mounting and operating instructions:
−Mounting and operating instructions for
e.g. Acccessories: Compensation chamber uEB2595
e.g. Type2NIStrainer uEB1015
−Data sheets for
e.g. Accessories:Compensationchamber·Screwttings·Control
lineconnection·Controlline uT2595
e.g. Type2NIStrainer uT1015
−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.

EB 2512 EN 1-5
Safety instructions and measures
1.2 Notes on possible personal injury
WARNING
!
Crush hazard arising from moving parts.
Theregulatorcontainsmovingparts(setpointsprings),whichcaninjurehandsorn-
gers if inserted into the regulator.
ÎDonotinserthandsorngersbetweenthesetpointspringswhiletheregulatoris
in operation.
ÎDonotinserthandsorngersbetweenthepillarsandsetpointspringswhilethe
regulator is in operation.
ÎDonotinserthandsorngersbetweenthespringplateandcrossbeamwhilethe
regulator is in operation.
ÎBeforeperforminganyworkontheregulator,depressurizetheplant.Disconnector
shut off the control line.
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 hearing loss or deafness due to loud noise.
The noise emissions depend on the valve version, plant facilities and process medium.
ÎWear hearing protection when working near the valve.
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.

1-6 EB 2512 EN
Safety instructions and measures
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.samson.de/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 due to loaded springs.
The set point springs of regulators with adjusted set point are preloaded and are under
tension.
ÎBeforestartinganyworkonthesprings,relievethecompressionfromthepreload-
ed springs.
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.

EB 2512 EN 1-7
Safety instructions and measures
NOTICE
!
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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 contamination of the process medium through the use of unsuitable lubricant
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.

1-8 EB 2512 EN
Safety instructions and measures
NOTICE
!
Risk of excess pressure damaging plant sections due to construction-related seat
leakage through the regulator.
ÎAlwaystasafetydevice(e.g.safetyexcesspressurevalveorsafetyreliefvalve)in
the plant.
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 plug or dia-
phragm stem guide.
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.
SAMSON's After-sales Service can support you concerning lubricant, tightening torques
and tools approved by SAMSON.
Note

EB 2512 EN 1-9
Safety instructions and measures
1.4 Warnings on the regulator
Warning Meaningofthewarning Location on the device
Attention !
Do not
disassemble the
valve without
relieving the
tension from the
set point spring.
Warning to indicate that the set point springs are
loaded.
There is a risk of serious head or face injury through the
sudden release of the set point springs while unscrewing
the crossbeam when the set point springs are loaded.
Completely relieve
the tension from
the set point
springs before
unthreading the
two nuts.
Warning to indicate that the set point springs are
loaded.
Thereisariskofinjurytohandsorngersthroughthe
sudden release of the actuator stem if they are inserted
betweenthecrossbeamandsetpointspringswhileex-
changing the actuator.
Unlock/unlockthe
plug stem
Warningtoindicatepropertydamageatthebellows
seal.
There is a risk of damage to the bellows seal due to the
incorrect mounting or removal of the plug stem.

1-10 EB 2512 EN
Safety instructions and measures

EB 2512 EN 2-1
Markings on the device
2 Markings on the device
Severalnameplatesareafxedtothedevice.Thenameplatesareusedtoidentifythesepara-
teregulatorcomponents(seeFig.2-1).
2.1 Nameplates
Valve nameplate
DIN version ANSI version
2314 5
11109876
2314 5
11109876
ANSIversion·DINversion
1 Valve type
2Modelnumberwithindex
3CongurationID
4 Order number or date
5 KVS/CV
6 Set point range or spring range
7Valvesize
8 Pressure rating
9 Perm. differential pressure
10 Perm. temperature
11 Bodymaterial
Actuator nameplate
DIN/ANSI version
1Actuatorarea(DIN/ANSI)
2 Actuator type designation
2.1 Valve type designation
3CongurationID
4 ID number
5YearofCEcertication
6.2
Max.perm.pressureattheactuator,
basedonthemax.adjustableset
point(DIN/ANSI)
7Valvesize(DIN/ANSI)
9Setpointrange(DIN/ANSI)
10 Diaphragm material
11 CE mark
12 Numberofcerticationbody
DIN/ANSIversion
6.2
22.1 34 1115
97 910 12
Fig.2-1: Nameplates of regulator parts

2-2 EB 2512 EN
Markings on the device
2.2 Locations of the nameplate
Location of the
nameplate on the
regulator
components
Fig.2-2: Nameplate of the Type2412 Valve
and on the Type2413 Actuator
(diaphragm or bellows)
2.3 Material numbers
2.3.1 Type 2412 Valve
Seethenameplate(11,ANSI/DINbodyma-
terial). For more details on the nameplate,
seesection2.1.
2.3.2 Type2413Actuator
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namepla-
te(3,ANSI/DINcongurationID).Formore
detailsonthenameplate,seesection2.1.

EB 2512 EN 3-1
Design and principle of operation
3 Design and principle of oper-
ation
ÎRefertoFig.3-1
The Type 41-23 Pressure Reducing Valve
consistsofaType2412ClosingValveanda
Type2413Actuator.Thevalveandactuator
(exceptfortestedregulators)aredelivered
separately and must be assembled together
according to these instructions (see the 'In-
stallation' section).
The pressure reducing valve is used to main-
tain 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 direc-
tion indicated by the arrow on the body. The
position of the valve plug determines the
owrateand,asaresult,thepressureratio
across the valve. The plug stem is sealed by
a frictionless bellows (5.1). The downstream
pressure p2is transmitted over the compen-
sation chamber (18) (for liquids above
150°Candforsteam)andthecontrolline
(17) to the operating diaphragm (12) (oper-
ating bellows (12.1) in the version with bel-
lows actuator) where it is converted into a
positioning force. This force is used to move
the valve plug depending on the force of the
set point springs (7). The spring force is ad-
justable at the set point adjuster (6). The
valves with KVS4andhigherhaveabalanc-
ing bellows (4). The upstream pressure acts
on the outside of the bellows and the down-
stream pressure on the inside of the bellows.
As a result, the forces produced by the up-
stream and downstream pressures acting on
the plug are balanced out.
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 (actua-
tor with two diaphragms).
The valve closes when the downstream pres-
sure rises.
LegendforFig.3-1
1Valve body
2Seat
3Plug
4Balancingbellows
5Plug stem
5.1 Bellows
6Set point adjuster
7Set point springs
7.1 Spring plate
8Crossbeam
8.1 Pillar(viewdrawnturnedby90°)
8.2 Nuts for pillars
8.3 Tapped holes
9Fastening nuts
10 Diaphragmactuator/bellowsactuator
11 Actuator stem
12 Operating diaphragm
12.1
Operating bellows
13 Diaphragm plate
14 Diaphragm plate nut
15 Nuts and bolts
16
ControllineconnectionG¼
(with screw joint with restriction when used
with steam)
17
Control line (to be provided on site)
(available as control line kit for direct
pressure tapping at the body uT2595)
18 Compensation chamber
19 Filler plug
20 Travel stop cap with cotter pin

3-2 EB 2512 EN
Design and principle of operation
2
3
4
5
6
7
5.1
10
11
12 16
1819
17
1
8
9
15
20
13
14
8.2
8.1
8.2
p1p2
7.1
Type 2412 Valve
Type2413DiaphragmActuator
12.1
16
8.2
10
Bellowsactuator for
DN15to50
8.3
10
16
Bellowsactuator for
DN65to100
Type2413BellowsActuatorfor2to6,5to10,10to22and20to28bar
Fig.3-1: Functional diagram for regulators, DN32 to 100 with balancing bellows

EB 2512 EN 3-3
Design and principle of operation
3.1 Additionalttings
ÎRefertoFig.3-2
Strainers
We recommend installing a SAMSON
strainer (2) upstream of the valve. It prevents
solid particles in the process medium from
damaging the regulator.
ÎDo not use the strainer to permanently
ltertheprocessmedium.
ÎSelectastrainer(meshsize)suitablefor
the process medium.
Any impurities carried along by the process
medium may impair the proper functioning
of the regulator. We recommend installing a
strainer (e.g. SAMSON Type2NI) upstream
of the pressure reducing valve (uEB1015).
Pressure gauges
Install a pressure gauge (3 and 5) both up-
stream and downstream of the regulator to
monitor the pressures prevailing in the plant.
Note
Control line connection in pipeline:
Controllineconnectionbelowthe
middleoftheange:
1 42 18 5 63
184
Min. pipe diameter ½“
Control line connection in manifold: Connectionabovethemiddleoftheange:
1 2 4
5
7
18
3
184
Hk
Hk= Additional condensate head
1Shut-off valve
2Strainer
3Upstream pressure gauge
4Pressure reducing valve
5Downstream pressure
gauge
6Shut-off valve
7Steam trap
18 Compensation chamber
Fig.3-2: Sample application

3-4 EB 2512 EN
Design and principle of operation
Bypass and shut-off valves
We recommend installing a shut-off valve (1
and 6) both upstream of the strainer and
downstream of the regulator and installing a
bypass line. The bypass ensures that the
plant does not need to be shut down for ser-
vice and repair work on the regulator.
Insulation
Regulators can be insulated to reduce heat
energy transfer.
Refer to the instructions in the 'Installation'
section.
Noise emission
Trimswithowdividerscanbeusedtore-
duce noise emission (uT2512).
The Type41-23 Regulator is not a safety
valve. If necessary, a suitable overpressure
protection must be installed on site in the
plant section.
3.2 Technical data
The valve and actuator nameplates provide
information on the valve and actuator ver-
sions (see the 'Markings on the device' sec-
tion).
More information is available in Data Sheet
uT2512.
Note
Note
Compliance
TheType41-23RegulatorbearsboththeCE
and EAC marks of conformity.
Process medium and scope of application
TheType41-23PressureReducingValveis
used to maintain the pressure downstream of
the regulator to an adjusted set point.
−For liquids, gases and vapors
−Max.temperature350°C
−Set points from 0.05to28bar
−ValvesizeDN15to100
−Pressure ratings from PN16to40
The regulator is open when relieved of pres-
sure. The valve closes when the downstream
pressure rises.
Temperature range
Dependingonhowtheregulatoriscong-
ured, it can be used up to temperatures of
350°C(seeTable3-1).Theminimumtem-
perature is limited by the accessories used
and the actuator's diaphragm material
(uT2595).
Leakage class
The metal-seated regulator has the leakage
classIaccordingtoIEC60534-4.
The soft-seated regulator has the leakage
classIVaccordingtoIEC60534-4.