Samson 42-34 Service manual

Translation of original instructions
EB 3013 EN
Differential Pressure Regulator with Flow Limitation
Type42-34·Type42-38
Self-operated Regulators · Closing Actuator
Type 42-34 Differential Pressure Regulator Type 42-38 Differential Pressure Regulator
Edition August 2021

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.
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 3013 EN

Contents
EB 3013 EN
1 Safety instructions and measures ................................................................1-1
1.1 Notes on possible severe personal injury ......................................................1-5
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 2423 Valve.........................................................................................2-2
2.3.2 Type2424andType2428Actuators............................................................2-2
3 Design and principle of operation ...............................................................3-1
3.1 Additionalttings........................................................................................3-4
3.1.1 Versions .....................................................................................................3-5
3.2 Technical data ............................................................................................3-6
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...........................................................................5-2
5.3 Installation..................................................................................................5-5
5.3.1 Installing the regulator.................................................................................5-6
5.4 Testing the regulator ....................................................................................5-6
5.4.1 Leak test.....................................................................................................5-7
5.4.2 Pressure test................................................................................................5-8
5.4.3 Filling the plant...........................................................................................5-9
5.4.4 Cleaning the pipeline ..................................................................................5-9
5.5 Insulation .................................................................................................5-10
6 Start-up .....................................................................................................6-1
6.1 Start-up and putting the device back into operation .......................................6-1
6.2 Starting up the plant....................................................................................6-2

Contents
EB 3013 EN
7 Operation..................................................................................................7-1
7.1 Adjusting the set points................................................................................7-1
7.1.1 Adjusting the differential pressure set point ...................................................7-1
7.1.2 Adjustingtheowlimitation.........................................................................7-3
7.1.3 Based on a known plant pressure drop .........................................................7-4
7.1.4 Based on an unknown plant pressure drop....................................................7-4
7.2 Pressure conditions in the plant and at the regulator.......................................7-5
7.3 Sample application .....................................................................................7-6
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.............................................................9-6
9.2 Installing the regulator after service work ......................................................9-6
9.3 Service work...............................................................................................9-6
9.4 Replacing the actuator.................................................................................9-6
9.5 Replacing the seat and plug.........................................................................9-7
9.6 Exchanging the operating diaphragm unit in the actuator ..............................9-7
9.6.1 Type2428Actuator ....................................................................................9-7
9.6.2 Type2424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 Lubricants.................................................................................................15-1
15.3 Tools ........................................................................................................15-1
15.4 Accessories ..............................................................................................15-1
15.5 Spare parts ..............................................................................................15-2
15.6 After-sales service.....................................................................................15-8

EB 3013 EN 1-1
Safety instructions and measures
1 Safety instructions and measures
Intended use
TheSAMSONType42-34andType42-38Regulatorsaredesignedasdifferentialpressure
regulatorswithowlimitation.TheyconsistofaType2423ValveandaType2424Actuator
(Type42-34)oraType2428Actuator(Type42-38).Theseregulatorcomponentsaredeliv-
ered separately.
Theself-operatedregulatorsareusedtocontrolthedifferentialpressureandlimittheow
rate. They are mainly used in district heating supply networks with indirect connection and in
industrial plants to control liquids.
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 3013 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 3013 EN 1-3
Safety instructions and measures
Safety features
TheTypes42-34and42-38Regulatorsdonothaveanyspecialsafetyfeatures.Whenre-
lieved of pressure, the regulators are opened 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 3013 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. 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 3013 EN 1-5
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.
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unnoticed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 given
by the plant operator.

1-6 EB 3013 EN
Safety instructions and measures
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.
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 preloaded
springs.
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 indicat-
ed on the SAMSON delivery note.
ÎInformation on safe use of the part affected uwww.samsongroup.com/en/
about-samson/material-compliance/reach-regulation/.