Samson 42-20 Service manual

Translation of original instructions
EB 3007 EN
Type42-20 and Type42-25 Differential Pressure Regulators
Self-operated Regulators · Opening Actuator
Type 42-20 Differential Pressure Regulator Type 42-25 Differential Pressure Regulator
Edition October 2022

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 3007 EN
Note on these mounting and operating instructions
These mounting and operating instructions assist you in mounting and operating the device
safely. The instructions are binding for handling SAMSON devices. The images shown in
these instructions are for illustration purposes only. The actual product may vary.
ÎFor the safe and proper use of these instructions, read them carefully and keep them for
later reference.
ÎIf you have any questions about these instructions, contact SAMSON‘s After-sales Service
([e-mail]).
The mounting and operating instructions for the devices are included
in the scope of delivery. The latest documentation is available on our
website at www.samsongroup.com > Service & Support > Downloads >
Documentation.

Contents
EB 3007 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.............................................................1-7
2 Markings on the device ..............................................................................2-1
2.1 Nameplates................................................................................................2-1
2.2 Location of the nameplates ..........................................................................2-2
2.3 Materialidenticationnumber .....................................................................2-2
2.3.1 Type 2422 Valve.........................................................................................2-2
2.3.2 Type2420andType2425Actuators............................................................2-2
3 Design and principle of operation ...............................................................3-1
3.1 Additionalttings........................................................................................3-4
3.2 Technical data ............................................................................................3-5
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............................................................4-2
4.3.1 Transporting the regulator............................................................................4-2
4.3.2 Lifting the regulator.....................................................................................4-3
4.4 Storing the regulator ...................................................................................4-4
5 Installation.................................................................................................5-1
5.1 Installation conditions..................................................................................5-1
5.2 Preparation for installation...........................................................................5-4
5.3 Installation..................................................................................................5-5
5.3.1 Installing the regulator.................................................................................5-6
5.4 Testing the regulator....................................................................................5-7
5.4.1 Leak test.....................................................................................................5-8
5.4.2 Pressure test................................................................................................5-8
5.4.3 Filling the plant...........................................................................................5-9
5.4.4 Cleaning the pipeline ................................................................................5-10
5.5 Insulation .................................................................................................5-10
6 Start-up .....................................................................................................6-1
6.1 Start-up and putting the regulator back into operation ...................................6-1
6.2 Starting up the plant....................................................................................6-2
7 Operation..................................................................................................7-1
7.1 Adjusting the differential pressure set point ...................................................7-1

Contents
EB 3007 EN
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.............................................................9-5
9.2 Installing the regulator after service work ......................................................9-5
9.3 Service work...............................................................................................9-5
9.4 Replacing the actuator.................................................................................9-6
9.5 Replacing the seat and plug.........................................................................9-6
9.6 Replacing the actuator's operating diaphragm ..............................................9-6
9.6.1 Type2420Actuator ....................................................................................9-6
9.6.2 Type2425Actuator ....................................................................................9-7
9.7 Ordering spare parts and operating supplies ................................................9-8
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..................................................................................................15-1
15.3 Tools........................................................................................................15-1
15.4 Accessories ..............................................................................................15-1
15.5 Spare parts ..............................................................................................15-2
15.6 After-sales service.....................................................................................15-6

EB 3007 EN 1-1
Safety instructions and measures
1 Safety instructions and measures
Intended use
TheSAMSONType42-20andType42-25Regulatorsaredifferentialpressureregulators.
TheyconsistofaType2422ValveandaType2420Actuator(Type42-20)oraType2425
Actuator(Type42-25).Theseregulatorcomponentsaredeliveredseparately.
The self-operated regulators are used to control the differential pressure in plants. Liquids,
gases and vapors in district heating system, extended heating systems or industrial plants
can be controlled by the regulators.
Theregulatorsaredesignedtooperateunderexactlydenedconditions(e.g.operatingpres-
sure, process medium, temperature). Therefore, operators must ensure that the regulators are
onlyusedinoperatingconditionsthatmeetthespecicationsusedforsizingthedevicesat
the ordering stage. In case operators intend to use the 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
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 3007 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substances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. Follow the instructions given by
the plant operator.
– 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. Plant operators and operat-
ingpersonnelmustobserveallhazardstatements,warningandcautionnotesinthese
mounting and operating instructions.
Hazardsresultingfromthespecialworkingconditionsattheinstallationsiteoftheregulator
mustbeidentiedinariskassessmentandpreventedthroughthecorrespondingsafetyin-
structions drawn up by the operator.
Wealsorecommendcheckingthehazardsposedbytheprocessmediumbeingused(e.g.
uGESTIS(CLP)hazardoussubstancesdatabase).
ÎObservesafetymeasuresforhandlingthedeviceaswellasrepreventionandexplosion
protection measures.
These mounting and operating instructions deals with the standard version of the device.
Components of the device that differ to those used for the standard version described in this
documentcanbeexchangedwithothercertainSAMSONcomponents.Theresidualhazards
of these components are described in the associated mounting and operating instructions
(see documents listed under 'Referenced documentation').

EB 3007 EN 1-3
Safety instructions and measures
Safety features
TheTypes42-20and42-25Regulatorsdonothaveanyspecialsafetyfeatures.Whenre-
lieved of pressure, the regulators are closed by the force of the set point springs.
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riskassessmentperformedinaccordancewithEN13463-1:2009,
section 5.2, the non-electrical regulators do not have their own potential ignition source even
in the rare incident of an operating fault. As a result, they do not fall within the scope of Di-
rective 2014/34/EU.
ÎForconnectiontotheequipotentialbondingsystem,observetherequirementsspeciedin
section6.4ofEN60079-14(VDE0165-1).

1-4 EB 3007 EN
Safety instructions and measures
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.
ÎIf necessary, a suitable overpressure protection must be installed on site in the plant
section.
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.
Referenced documentation
The following documents apply in addition to these mounting and operating instructions:
– Mounting and operating instructions for
e.g. Type2N/NI Strainer uEB1015
– Data sheets for
e.g. Accessories · Differential pressure and ow regulators uT3095
e.g. Type2N/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.).

EB 3007 EN 1-5
Safety instructions and measures
1.2 Notes on possible personal injury
WARNING
!
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. Follow the instructions giv-
en by the plant operator.
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.
ÎBeforeperforminganyworkontheregulator,depressurizetheplant.Disconnector
shut off the control line.
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.

1-6 EB 3007 EN
Safety instructions and measures
WARNING
!
Risk of personal injury due to pressurized components and process medium being
discharged.
Incorrect opening of pressure equipment or mounting parts may lead to the process
medium escaping to the atmosphere.
ÎDonotloosenthecontrollinewhilethevalveispressurized.
ÎDo not start up the regulator until all parts have been mounted.
Risk of burn injuries due to hot or cold components and pipelines.
Depending on the process medium, regulator components and pipelines may get very
hot or cold and cause burn injuries.
ÎAllow components and pipelines to cool down or warm up to the ambient tempera-
ture.
ÎWear protective clothing and safety gloves.
Damage to health relating to the REACH regulation.
If a SAMSON device contains a substance which is listed as being a substance of very
high concern on the candidate list of the REACH regulation, this circumstance is indi-
cated on the SAMSON delivery note.
ÎInformation on safe use of the part affected uwww.samsongroup.com/en/
about-samson/material-compliance/reach-regulation/.
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.