Samson 42-36 Service manual

Translation of original instructions
EB 3015 EN
Type 42-36 Flow Regulator
Self-operated 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
([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 3015 EN

Contents
EB 3015 EN 1
1 Safety instructions and measures ................................................................1-1
1.1 Notes on possible severe personal injury ......................................................1-4
1.2 Notes on possible personal injury ................................................................1-4
1.3 Notes on possible property damage.............................................................1-6
2 Markings on the device ..............................................................................2-1
2.1 Nameplates................................................................................................2-1
2.2 Location of the nameplates ..........................................................................2-2
2.3 Material numbers........................................................................................2-2
2.3.1 Type 2423 Valve.........................................................................................2-2
2.3.2 Type2426Actuator ....................................................................................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 and assembly ...........................................................................5-1
5.1 Installation conditions..................................................................................5-1
5.2 Preparation for installation...........................................................................5-3
5.3 Installation..................................................................................................5-5
5.3.1 Installing the regulator.................................................................................5-5
5.3.2 Cleaning the pipeline ..................................................................................5-6
5.4 Checking the regulator ................................................................................5-6
5.4.1 Leak test.....................................................................................................5-7
5.4.2 Pressure test................................................................................................5-8
5.5 Insulation ...................................................................................................5-8
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
6.2.1 Control of liquids ........................................................................................6-2
6.2.2 Control of steam .........................................................................................6-2

Contents
2 EB 3015 EN
7 Operation..................................................................................................7-1
7.1 Adjusting the set point.................................................................................7-1
7.2 Adjustingtheowrate ................................................................................7-2
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...............................................................................................9-6
9.3.1 Replacing the actuator.................................................................................9-6
9.3.2 Replacing the seat and plug.........................................................................9-7
9.3.3 Replacing the actuator's 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 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.....................................................................................15-7

EB 3015 EN 1-1
Safety instructions and measures
1 Safety instructions and measures
Intended use
TheSAMSONType42-36Regulatorisaowregulator.ItconsistsofaType2423Valveand
aType2426Actuator.Thetestedregulatorisdeliveredasanassembledunit.
Theself-operatedregulatorisusedtocontroltheowrateinpipelines.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 3015 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
−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substancesdatabase).
ÎObservesafetymeasuresforhandlingthedeviceaswellasrepreventionandexplosion
protection measures.
Safety features
TheType42-36Regulatordoesnothaveanyspecialsafetyfeatures.Whenrelievedof
pressure, the regulator is opened by the force of the set point springs.

EB 3015 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.
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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).
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.).

1-4 EB 3015 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.
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.

EB 3015 EN 1-5
Safety instructions and measures
WARNING
!
Risk of personal injury due to pressurized components and process medium escap-
ing under pressure.
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.
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.
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.

1-6 EB 3015 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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'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.

EB 3015 EN 1-7
Safety instructions and measures
NOTICE
!
Risk of contamination of the process medium through the use of unsuitable lubri-
cants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.
SAMSON's After-sales Service can support you concerning lubricant, tightening torques
and tools approved by SAMSON.
Note

1-8 EB 3015 EN
Safety instructions and measures

EB 3015 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sepa-
rateregulatorcomponents(seesection2.1).
2.1 Nameplates
NameplatesofType2423Valve
DINversion ANSI version
2314 5
11109876
2314 5
11109876
ANSI version · DIN version
1 Valve type
2 Model number with index
3 Material number
4 Order number or date
5 KVS/CV
6Set point range or spring
range
7Valvesize
8 Pressure rating
9 Perm. differential pressure
10 Perm. temperature
11 Bodymaterial
NameplateofType2426Actuator
DIN/ANSIversion
1Actuatorarea(DIN/ANSI)
2 Type
3 Material number and device index
4IDnumber
5YearwhentheCEcerticationwas
issued
6.1 PressureratinginPN/Class(DIN/
ANSI)
7Valvesize(DIN/ANSI)
9Differentialpressureacrossthe
restriction(DIN/ANSI)
10 Diaphragmmaterial
11 CE marking
12 Certicationbodynumber
DIN/ANSIversion
6.1
2341 511
7910912
Fig.2-1: Nameplates of regulator parts

2-2 EB 3015 EN
Markings on the device
2.2 Location of the nameplates
Location of the
nameplate on the
regulator
components
Fig.2-2: Nameplates of the Type2423 Valve
and the Type2426 Diaphragm
Actuator
2.3 Material numbers
2.3.1 Type2423Valve
Seethenameplate(11forDIN/ANSIver-
sion, body material). For more details on the
nameplate,seesection2.1.
2.3.2 Type2426Actuator
Specifying the material number, you can
contactustondoutwhichmaterialisused.
Thisisspeciedonthenameplateinthe
'MNo.'eld(3forDIN/ANSI).Formorede-
tailsonthenameplate,seesection2.1.

EB 3015 EN 3-1
Design and principle of operation
3 Design and principle of oper-
ation
ÎSeeFig.3-1andFig.3-2
Type42-36·Theowregulatorisusedto
limittheowrateinthepipeline.Theset
point is adjusted at the restriction.
The regulator basically consists of a
Type2423Valvewithseat,plugandset
pointadjusteraswellasaType2426Actua-
tor (closing) with operating diaphragm.
Valve and actuator are delivered separately
and must be fastened together on site using
a coupling nut.
Type42-36DoT·Thisversioncanalsocon-
trol or limit the temperature by mounting a
double adapter with thermostat. Read the
mounting and operating instructions:
uEB3019fordoubleadapterDoT
and
uEB2231forType2231to2235Control
Thermostats
Themediumowsthroughthevalveinthe
direction indicated by the arrow. The areas
released by the restriction (1.4) and the
valveplug(3)determinetheowrate.
In fully balanced valves, the forces acting on
the valve plug created by the upstream and
downstream pressures are balanced by a
balancing bellows (5) or balancing dia-
phragm(5.1)(DN65to250,balancedbya
diaphragm).
Regulators balanced by a bellows or a dia-
phragm only differ in the pressure balancing
principle applied. Valves balanced by a dia-
phragm have a balancing diaphragm (5.1)
instead of the balancing bellows (5). The
downstream pressure p2acts on the bottom
of the diaphragm and the upstream pressure
p1on the top of the diaphragm. As a result,
the forces created by the upstream and
downstream pressures acting on the plug are
balanced out.
The pressure upstream of the restriction (1.4)
is transferred over the control line (18) to the
bottom diaphragm chamber and the
pressure downstream of the restriction (1.4)
is transferred through the hollow plug stem
(7) past the diaphragm stem (6) to the top
diaphragm chamber of the actuator. This
differential pressure creates a positioning
force at the operating diaphragm (12),
which moves the valve plug depending on
the force of the differential pressure springs
(14).Forexample,iftheowrateincreases,
the differential pressure (at the restriction)
increases as well. The actuator and plug
stems move in the closing direction, causing
theowratetodecreaseuntilitreachesthe
set point adjusted at the restriction (1.4).
Whentheowratestartstodrop,the
described procedure is reversed.

3-2 EB 3015 EN
Design and principle of operation
15
6
18
11
14
12
5
8
7
3
2
1
1.3
1.1
1.2
+
16
17
1.4
19
Type2423Valvebalanced by a
bellows
Type2426
Actuator
Fig.3-1: Functional diagram for regulators, DN15 to 250 with balancing bellows

EB 3015 EN 3-3
Design and principle of operation
1
2
3
p
5.
1
16
6
14
18
7
15
11
12
17
1.3
1.
1
1.
2
1.4
p2
1
19
Type2423Valve
balanced by a diaphragm
Type2426
Actuator
Fig.3-2: Functional diagram for regulators, DN65 to 250 with balancing diaphragm
LegendforFig.3-1andFig.3-2
1 Valve body
1.1 Setpointadjusterforowrate
1.2 Lock nut
1.3 Cap
1.4 Restriction
2 Seat
3 Plug
5Balancingbellows
5.1 Balancingdiaphragm
6Diaphragmstem
7 Plug stem
8Ventplug(DN125andlarger)
11 Coupling nut
12 Operating diaphragm
14 Differentialpressuresprings
15 Screws
16 Diaphragmplate
17 Nut
18 High-pressure control line
19 Control line connection

3-4 EB 3015 EN
Design and principle of operation
3.1 Additionalttings
ÎSeeFig.3-3
Pressure gauges
Install a pressure gauge at a suitable point to
monitor the pressures prevailing in the plant
(3 and 5).
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.
Type42-36installedintheowpipe(T>150°C):
Type42-36installedinthereturnowpipe
(T<150°C):
6 5
31 2 188 4
+
7
Type42-36installedintheow
pipe(T>150°C)
6 5
31 2
4
+
7
Type42-36installedinthereturn
owpipe(T<150°C)
1 Shut-off valve
2 Strainer
3Pressuregauge(owpipe)
4 Flow regulator
5Pressuregauge(returnowpipe)
6 Shut-off valve
7Motorizedvalve
8 Needle valve
18 Compensation chamber
(optional)
∆pmin Minimum differential pressure across the valve in bar
∆prestriction Differentialpressurecreatedattherestrictionfor
measuringtheowrateintheregulator
V Adjustedowrateinm³/h
KVS Valveowcoefcientinm³/h
·
The minimum required plant differential pressure
∆pminacrossthevalveiscalculatedasfollows: Δpmin=Δprestriction +
(
V
)
2
KVS
·
Fig.3-3: Installation example: Type42-36 installed in the ow and return ow pipe

EB 3015 EN 3-5
Design and principle of operation
Strainer
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).
Insulation
Regulators can be insulated to reduce heat
energy transfer.
Refer to the instructions in the 'Installation'
section.
The Type42-36 Regulator is not a safety
valve. If necessary, a suitable overpressure
protection must be installed on site in the
plant section.
Note
Note
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3015.
Compliance
TheType42-36RegulatorbearsboththeCE
and EAC marks of conformity.
Process medium and scope of application
TheType42-36FlowRegulatorisdesigned
tomaintaintheowrateinaplanttothead-
justed set point.
−For liquids, gases and vapors
−Max. temperature 150°C/220°C1)
−Set points from 0.05to520m³/h
−ValvesizeDN15to250
−Pressure ratings from PN16to40
The regulator is open when relieved of
pressure. The valve closeswhentheowrate
rises.
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.
Note

3-6 EB 3015 EN
Design and principle of operation
Table3-1: Technical data · All pressures in bar (gauge)
Type2423Valve·Balancedbyabellows
Valvesize DN15to250
Pressure rating PN16,25or40
Max. permissible
temperature
Valve body See pressure-temperature diagram in uT3000
Actuator
Withcompensationchamber:steamandliquidsupto220°C·
Withoutcompensationchamber:liquidsupto150°C,airand
nitrogenupto150°C1)
Set point (differential pressure at restriction) 0.2bar·0.5bar
LeakageclassaccordingtoIEC60534-4 ≤0.05%ofKVScoefcient
Conformity ·
RefertoFig.3-4fortheassignmentofactuatorandvalve
Type2423Valve·Balancedbyadiaphragm
Valvesize DN65to250
Pressure rating PN16,25or40
Max. permissible
temperature
Valve body See pressure-temperature diagram in uT3000
Actuator Water150°C·Airandgases80°C
Set point (differential pressure at restriction) 0.2bar·0.5bar
LeakageclassaccordingtoIEC60534-4 ≤0.05%ofKVScoefcient
Conformity ·
RefertoFig.3-4fortheassignmentofactuatorandvalve
1) Specialversion:valvewithoricestemsealandoperatingdiaphragmmadeofFKM
Temperature range
Dependingonhowtheregulatoriscong-
ured, it can be used up to temperatures of
220°C(seeTable3-1).Theminimumtem-
perature is limited by the accessories used
and the actuator's diaphragm material
(uT3015).
Noise emissions
SAMSON is unable to make general state-
ments about noise emissions. The noise emis-
sions depend on the regulator version, plant
facilities, process medium and operating
conditions.
Dimensions and weights
Table 3-4 and Table 3-5 provide a summary
of the dimensions and weights. The lengths
and heights in the dimensional drawings are
shownonpage3-10.