Samson 42-36 Service manual

Self-operated Regulators
Flow Regulator
Type 42-36
Mounting and
Operating Instructions
EB 3015 EN
Edition December 2008
Type 42-36

Contents Page
1 Design and principle of operation . . . . . . . . . . . . . . . . . . . 4
2 Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2.1 Mounting position . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2.2 Control line, equalizing tank and needle valve . . . . . . . . . . . . . . 7
2.3 Strainer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
2.4 Shut-off valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
2.5 Pressure gauge. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
3 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
3.1 Start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
3.2 Set point adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . 9
3.3 Decommissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
4 Maintenance · Troubleshooting . . . . . . . . . . . . . . . . . . . . 14
4.1 Replacing the diaphragm . . . . . . . . . . . . . . . . . . . . . . . 14
5 Customer service . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
6 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
7 Nameplates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
8 Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
2EB 3015 EN
Contents
CAUTION!
CAUTION indicates a hazardous situation
which, if not avoided, may result in injury.
NOTICE
NOTICE indicates a property damage
message.
Note: Supplementary explanations, informa-
tion and tips
Definitions of the signal words used in these instructions

EB 3015 EN 3
Safety instructions
General safety instructions
4
The regulators must be installed, started up and serviced by fully trained and
qualified personnel only, observing the accepted industry codes and
practices. Make sure employees or third persons are not exposed to any
danger.
4
The regulator complies with the requirements of the European Pressure
Equipment Directive 97/23/EC. The declaration of conformity issued for a
valve bearing the CE marking includes information on the applied conformity
assessment procedure.
The declaration of conformity can be provided on request.
4
For appropriate operation, make sure that the regulator is only used in
applications where the operating pressure and temperatures do not exceed
the operating values based on the sizing data submitted in the order.
Note that the manufacturer does not assume any responsibility for damage
caused by external forces or any other external factors.
4
Any hazards which could be caused in the regulator by the process medium or
operating pressure are to be prevented by means of appropriate measures.
4
Proper shipping and appropriate storage are assumed.
Note: Non-electric valve versions which do not have a valve body lined with an insulating
coating do not have their own potential ignition source according to the ignition risk assessment
stipulated in EN 13463-1: 2002, section 5.2, even in the rare incident of an operating fault.
Therefore, they do not fall within the scope of Directive 94/9/EC.
For connection to the equipotential bonding system, observe the requirements specified in
section 6.3 of EN 60079-14: 2003 (VDE 0165 Part 1).

1 Design and principle of
operation
The flow regulator is designed to maintain the
flow rate in the pipeline at the set point ad-
justed at the restriction.
The regulator consists of a Type 2423 Valve
with a seat, plug and a restriction as well as a
Type 2426 Closing Actuator with an operat-
ing diaphragm.
The valve and actuator are delivered as sepa-
rate units and must be connected with a cou-
pling nut on site.
Type 42-36 DoT
This version allows the additional control or
limitation of the temperature by attaching a
double adapter with a thermostat.
See the Mounting and Operating Instructions:
EB 3019 EN for the double adapter and
EB 2231 EN for Type 2231, Type 2232,
Type 2233, Type 2234 and Type 2235 Control
Thermostat.
The medium flows through the valve in the di-
rection indicated by the arrow. The flow rate
is determined by the free area between the re-
striction (1.1) and the valve plug (3).
The valve plug is unaffected by pressure
changes in the medium since the upstream
and downstream pressures are balanced by
the balancing bellows (5) or the balancing di-
aphragm (5.1) (DN 125 to 250/valve bal-
anced by a diaphragm).
The principle of operation of the regulators
with valves balanced by a bellows or dia-
phragm only differ concerning the pressure
balancing. The valves balanced by a dia-
phragm have a balancing diaphragm (5.1)
instead of a bellows (5). The downstream
pressure p2acts on the inside and the up-
stream pressure p1on the outside of the dia-
phragm or bellows. As a result, the forces act-
ing on the valve plug are balanced out.
The high pressure upstream of the restriction
(1.1) is transmitted through the control line
(18) to the lower diaphragm chamber. The
low pressure downstream of the restriction
(1.1) passes through the hollow plug stem (7)
and the diaphragm stem (6) into the top dia-
phragm chamber of the actuator. The differ-
ential pressure produced at the restriction is
converted into a positioning force at the oper-
ating diaphragm (12) and is used to move the
valve plug according to the force of the differ-
ential pressure springs (14). If the flow rate in-
creases, for example, the differential pressure
at the restriction also increases. The actuator
and plug stems move in the closing direction
and the flow rate is reduced until the flow rate
set point adjusted at the restriction (1.1) is
reached. If the flow rate decreases, the re-
verse takes place.
4EB 3015 EN
Design and principle of operation

EB 3015 EN 5
Design and principle of operation
Fig. 1 · Sectional drawing of regulator with valve balanced by a bellows
14
12
15
11
6
18
5
8
7
3
2
1
1.3
1.1
1.2
+
16
17
1.4
Type 42-36 · Balanced by a bellows
DN 15 to 250
Type 2423 Valve
balanced by a
bellows
Type 2426
Actuator
1 Valve body
1.1 Restriction (set point adjustment)
1.2 Lock nut
1.3 Cap
1.4 Orifice
2 Seat
3 Plug
5 Balancing bellows
6 Diaphragm stem
7 Plug stem
8 Venting (DN 125 and higher)
11 Coupling nut
12 Operating diaphragm
14 Differential pressure
spring(s)
15 Screws
16 Diaphragm plate
17 Nut
18 High-pressure control line

2 Installation
Install the regulator in the low-pressure line
(return flow) or in the high-pressure line (flow)
of the plant. Refer to installation schematics in
Fig. 4.
On selecting the position of installation, make
sure that the regulator can still be easily ac-
cessed after completion of the plant.
NOTICE
The regulator must be installed free of stress. If
necessary, support the piping near the con-
nections. However, do not attach supports to
the valve or actuator.
6EB 3015 EN
Design and principle of operation · Installation
Fig. 2 · Sectional drawing of regulator with valve balanced by a diaphragm
Type 42-36 · Balanced by a diaphragm · DN 125 to 250
1 Valve body
1.1 Restriction
(set point adjustment)
1.2 Lock nut
1.3 Cap
1.4 Orifice
2 Seat
3 Plug
5.1 Balancing diaphragm
6 Diaphragm stem
7 Plug stem
11 Coupling nut
12 Operating diaphragm
14 Differential pressure
spring(s)
15 Screws
16 Diaphragm plate
17 Nut
18 High-pressure control line
Type 2426
Actuator
Type 2423 Valve
balanced by a
diaphragm

Note: Install a strainer (e.g. SAMSON
Type 2 N/2 NI) upstream of the regulator to
prevent sealing particles, welding spatter or
other impurities carried along by the process
medium from impairing the proper function-
ing of the valve, especially tight shut-off.
2.1 Mounting position
See Fig. 3 for permissible mounting positions.
Standard mounting position · Install valve
without actuator in a horizontal pipeline with
the connection for the actuator facing down-
wards. Make sure the medium flows through
the valve in the direction indicated by the ar-
row. Then connect the actuator to the valve
using the coupling nut (11).
NOTICE
Protect the regulator when it is used to control
freezing process media.
On shutting down the plant in areas not free
from frost, depressurize and empty the regu-
lator and remove it from the pipeline.
2.2 Control line, equalizing tank
and needle valve
Control line · After mounting the actuator,
fasten the supplied high-pressure control line
to the regulator as shown in Figs. 1 and 2.
Control line kit · A control line kit for tapping
pressure directly at the valve body is avail-
able as an accessory from SAMSON. Refer to
Data Sheet T 3095 EN.
Equalizing tank · An equalizing tank is re-
quired for liquids above 150 °C and for
steam. For the control line, install the equaliz-
ing tank directly downstream of the pressure
tapping point at the valve. The mounting posi-
tion of the equalizing tank is indicated by an
adhesive label on the tank itself as well as by
an arrow and the word "top" stamped onto
the top of the tank. Adhere to the mounting
position and distances prescribed, otherwise
the safe functioning of the regulator cannot
be guaranteed.
Needle valve · If the regulator tends to hunt,
we recommend installing a SAMSON needle
valve in the control line routed on site at the
actuator connection.
EB 3015 EN 7
Installation
Fig. 3 · Permissible mounting positions
–All versions in DN 15 to 80
and up to max. 80 °C
–Standard mounting position
– all versions –
–Above 80 °C,
steam applications
–Only versions with fixed
plug guide and
up to max. 80 °C

Note: Needle valves, equalizing tanks and
compression-type screw fittings can be sup-
plied as required. These accessories are listed
in the Data Sheet T 3095 EN.
2.3 Strainer
A strainer installed in the flow pipe prevents
foreign matter and dirt particles in the me-
dium from entering the regulator. The
SAMSON product range includes the
Type 2 N/2 NI Strainer (refer to Data Sheet
T 1010 EN).
Install the strainer upstream of the regulator.
Make sure the direction of medium flow cor-
responds with the direction indicated by the
arrow on the strainer. The filter element must
be suspended downwards or be located at
the side for applications with steam. Remem-
ber to leave enough space to remove it.
2.4 Shut-off valve
We recommend installing a hand-operated
shut-off valve (Fig. 4) both upstream of the
strainer and at the outlet of the return flow
pipe to be able to shut down the plant for
8EB 3015 EN
Installation
Fig. 4 · Typical installation of Type 42-36, installed in the flow and return flow pipes
1 Shut-off valve
2 Strainer
3 Flow regulator
4 Equalizing tank (optional)
5 Needle valve
6 Pressure gauge
The minimum required plant pressure drop Δpmin
across the valve is calculated from:
Δpmin =Δprestriction +V
K
.
VS
⎛
⎝
⎜
⎜
⎞
⎠
⎟
⎟
2
Δp in bar
V
.in m3/h
KVS in m3/h
16
6
12
3
+
1
Type 42-36 installed in the return flow pipe
(T <150 °C)
16
61 24
53
+
Type 42-36 installed in the flow pipe
(T >150 °C)

cleaning and maintenance, and when the
plant is not used for longer periods of time.
2.5 Pressure gauge
To monitor the pressures in the plant, install a
pressure gauge both upstream and down-
stream of the regulator.
3 Operation
3.1 Start-up
CAUTION!
First start up the regulator after mounting all
the components, e.g. valve, actuator and con-
trol line.
Make sure the control line (and needle valve)
is open and correctly connected before
start-up.
For media temperatures above 150 °C
(steam), fill the equalizing tank with the pro-
cess medium (water) before start-up.
Note: On filling the plant, make sure the re-
striction (1.1) is open by turning the adjust-
ment screw counterclockwise as far as it will
go.
4Open all the valves on the consumer side.
Slowly open the shut-off valves starting on
the return flow pipe first. In case of valves
balanced by a bellows in DN 125 or
larger, vent the bellows housing at the
stopper (8) located at the side of the bel-
lows housing.
Rinsing the plant · After filling the plant, first
completely open the consumers. Open the re-
striction. Rinse out the pipeline at full flow rate
for several minutes. Check the installed
strainer (e.g. by measuring the pressure
drop) afterwards. Clean the strainer, if neces-
sary.
NOTICE
When testing the pressure of the plant when
the regulator is already installed, the pressure
must not exceed the nominal pressure of the
valve by 1.5 times nor the maximum permissi-
ble differential pressure in the actuator.
3.2 Set point adjustment
The control valves and shut-off valves as well
as all consumers or a bypass valve, if appli-
cable, must be opened to allow the maximum
flow rate to be reached.
Turn the restriction (1.1) until the required
flow rate is reached, by reading, for exam-
ple, the flow rate reading off a heat meter (re-
fer to Table 1 · Flow rate set point ranges).
Note: Always start the adjustment from a
closed restriction!
4Turn clockwise to close the restriction. This
reduces the flow rate.
4Turn counterclockwise to open the restric-
tion. This raises the flow rate.
You can also use the adjustment diagrams for
water in Figs. 5 to 7 to help you make the flow
rate adjustment.
EB 3015 EN 9
Operation

In these diagrams, the flow rates are listed by
how many turns of the set point adjustment
are required depending on the differential
pressure at the restriction 0.2 bar or 0.5 bar.
Note: The differential pressure at the restric-
tion
Δ
p
restriction
is fixed at either 0.2 bar or
0.5 bar (see the nameplate).
4Unscrew cap (1.3) and undo lock nut
(1.2). Turn the adjustment screw clockwise
as far as it will go.
4Find the flow set point in the diagram and
determine how many turns are required.
4Turn the screw counterclockwise (based
on a closed restriction) until the selected
set point is adjusted.
4Check the flow rate at the heat meter and
correct, if necessary.
4When the required flow rate is reached,
lock the screw in position with the lock nut
(1.2) and screw cap (1.3) back on.
Lead-seal cap, if necessary.
10 EB 3015 EN
Operation · Set point adjustment
Table 1 · Flow rate set point ranges V
.for water
Type 2423 · Balanced by a bellows
Nominal size DN 15 20 25 32 40 50 65 80 100 125 150 200 250
Differential pressure
at the restriction
Δprestriction = 0.2 bar
Flow rate set point ranges V
.for water in m3/h
0.05
to 2 0.15 to 3 0.25 to 3.5 0.4 to 70.6 to 11 0.9 to 16 2 to 28 3.5 to 35 6.5 to 63 11 to 80 18 to 120 20 to 180 26 to 220
Differential pressure
at the restriction
Δprestriction = 0.5 bar
0.15
to 3 0.25 to 4.5 0.4 to 5.3 0.6 to 9.5 0.9 to 16 2 to 24 3.5 to 40 6.5 to 55 11 to 90 18 to 120 20 to 180 26 to 260 30 to 300
Max. perm. differen-
tial pressure Δp25 bar 20 bar 16 bar 12
bar 10 bar
Nominal size DN 125 150 200 250
Differential pressure
at the restriction
Δprestriction = 0.2 bar
Flow rate set point ranges V
.for water in m3/h
11 to 120 18 to 180 20 to 320 26 to 350
Max. perm. differen-
tial pressure Δp12 bar 10 bar
Type 2423 · Balanced by a diaphragm

EB 3015 EN 11
Set point adjustment · Operation
Fig. 5 · Adjustment diagrams for Type 2423 balanced by a bellows, DN 15 to 80
Turns of set point adjustment (restriction)
Turns of set point adjustment (restriction)
– – – – Δprestriction = 0.5 bar
________ Δprestriction = 0.2 bar
Adjustment diagrams for water

12 EB 3015 EN
Operation · Set point adjustment
Fig. 6 · Adjustment diagrams for Type 2423 balanced by a bellows, DN 100 to 250
Turns of set point adjustment (restriction)
Turns of set point adjustment (restriction)
Adjustment diagrams for water
– – – – Δprestriction = 0.5 bar
________ Δprestriction = 0.2 bar

3.3 Decommissioning
Close the shut-off valves starting from the flow
pipe side (high-pressure line).
EB 3015 EN 13
Set point adjustment · Operation
Fig. 7 · Adjustment diagrams for Type 2423 balanced by a diaphragm, DN 125 to 250
DN 200, DN 250 · A = 320 cm²
Δprestriction = 0.2 bar · Balanced by a diaphragm
DN 125, DN 150 · A = 320 cm²
Δprestriction= 0.2 bar · Balanced by a diaphragm
Turns of set point adjustment (restriction)
Adjustment diagrams for water

4 Maintenance ·
Troubleshooting
The flow regulators are maintenance free.
Nevertheless, they are subject to natural
wear, particularly at the seat, plug and oper-
ating diaphragm.
Depending on the operating conditions, the
regulator needs to be checked at regular in-
tervals to avoid possible malfunctions.
CAUTION!
On performing any work on the regulator,
make sure the relevant section of the pipeline
is depressurized and, depending on the pro-
cess medium, drained as well.
For high temperatures, allow the regulator to
cool down to ambient temperature before
starting any work on it.
Interrupt or shut off the control line to avoid
any hazards which could be caused by mov-
ing parts.
As valves are not free of cavities, remember
that residual process medium might still be
contained in the valve.
We recommend to remove the valve from the
pipeline. Make sure that all the plant sections
connected to the control line are also
depressurized. If this is not the case, shut off
the control line.
Details on malfunctions and the recom-
mended action can be found in the Ta-
ble 2 · Troubleshooting.
Proceed as described in section 4.1 if the op-
erating diaphragm is defective.
4.1 Replacing the diaphragm
If only the diaphragm is defective, the control
line can be unscrewed and the actuator sepa-
rated from the valve after the relevant section
of the plant has been drained without having
to remove the valve from the pipeline.
1. Undo screws (15) at actuator and remove
the top cover plate together with the actu-
ator stem and spring assembly.
2. Unscrew nut (17), while holding the bot-
tom diaphragm stem stationary using a
suitable tool.
3. Lift off diaphragm plate (16) and pull out
diaphragm.
4. Insert a new diaphragm (12).
5. Proceed in the reverse order to reassem-
ble the actuator.
Start up as described in section 3.1.
14 EB 3015 EN
Maintenance · Troubleshooting

EB 3015 EN 15
Maintenance · Troubleshooting
Malfunction Possible reasons Recommended action
Flow rate exceeds the
flow rate set point V
.
Seat and plug untight Remove valve from pipeline. Clean seat and plug. Replace plug, if necessary. Otherwise
send the regulator to SAMSON for repair.
Operating diaphragm
defective Replace diaphragm (see section 4.1) or send the regulator to SAMSON for repair.
Control line blocked Remove control line and clean it.
Valve too large for control task Recalculate KVS coefficient and contact
SAMSON for further action.
Flow rate does not
reach the flow rate set
point V
.
Seat and plug untight Remove valve from pipeline. Clean seat and plug. Replace plug, if necessary. Otherwise
send the regulator to SAMSON for repair.
Wrong set point range selected Check set point range and contact SAMSON
for further action.
Safety equipment, e.g.
pressure limiter, has been
triggered Check plant and unlock safety equipment.
Insufficient pressure drop
across the plant
Compare existing differential pressure in the
plant with the plant’s drag.
Min. differential pressure across the plant
Δp = Δprestriction + (VK
.
VS
/)².
Strainer blocked Drain and clean filter of the strainer
Direction of flow, valve
incorrectly installed Install the valve so that the direction of flow is the same as indicated by the arrow.
Control loop hunts
Valve too large for control task Recalculate KVS coefficient. Contact
SAMSON.
Restriction (or needle valve) is
missing in a control line to
dampen pulsation
Install a needle valve in the control line and
start to close it until the control loop becomes
stable.
Caution! Do not completely close needle
valves.
Contact SAMSON if the malfunction cannot be remedied using the above table
Table 2 · Troubleshooting

5 Customer service
Should any malfunctions or any defect occur, SAMSON's After-Sales Service is prepared to
help you on site.
You can also send the defective regulator directly to your local SAMSON representative for re-
pair. Addresses of SAMSON subsidiaries, agencies and service centers are listed in the prod-
uct catalogs and in the Internet at www.samson.de.
To allow SAMSON to find the fault and to have an idea of the installation situation, specify the
following details (refer to the nameplate):
4Type and nominal size of the valve
4Order number and model number
4Upstream and downstream pressure
4Flow rate in m3/h
6 Technical data
16 EB 3015 EN
Customer service
Table 3 · Technical data · Type 42-36
Type 2423 Valve · Balanced by a bellows
Nominal size DN 15 to 250
Nominal pressure PN 16, 25 or 40 (acc. to DIN EN 12516-1)
Max. perm.
temperature
Valve body See pressure-temperature diagram (depending on material)
Actuator With equalizing tank: Liquids up to 220 °C
Without equalizing tank: Liquids up to 150 °C
Air and gases up to 80 °C
Set point (diff. pressure at restriction) 0.2 bar · 0.5 bar
See section 8 for assignment of actuator and valve
Type 2423 Valve · Balanced by a diaphragm
Nominal size DN 125 to 250
Nominal pressure PN 16, 25 or 40 (acc. to DIN EN 12516-1)
Max. perm.
temperature
Valve body See pressure-temperature diagram (depending on material)
Actuator Water: Up to 150 °C · Air and non-flammable gases: Up to 80 °C
Set point (diff. pressure at restriction) 0.2 bar · 0.5 bar
See section 8 for assignment of actuator and valve
4Min. and max. flow rates
4Has a strainer been installed?
4Sketch of the installation with exact
position of regulator and all additional
installed components (shut-off valves,
pressure gauges, etc.).

7 Nameplates
EB 3015 EN 17
Nameplates
Fig. 8 · Nameplates
Actuator nameplate
Valve nameplates
ANSI version
DIN version
Valve
1 Valve type
2 Model number
3 Model number index
4 Order number or order date
5K
VS coefficient
8 Nominal size
9 Nominal pressure
10 Perm. differential pressure in bar
11 Perm. temperature in °C
12 Body material
ANSI version
5 Nominal size
8 Perm. differential pressure in psi
9 Perm. temperature in °F
10 Body material
11 CVcoefficient (KVS x 1.17)
12 ANSI Class (pressure rating)
Actuator
1 Model number
2 Model number index
3 Order number or order date
4 Effective diaphragm area
5 Labeling acc. to DIN
6 Labeling acc. to ANSI
7 Max. perm. pressure
8 Nominal size
9 Differential pressure at restriction
10 Set point range
11 Diaphragm material
12 Year of production

8 Dimensions
18 EB 3015 EN
Dimensions
Fig. 9 · Dimensions and weights, Type 42-36 with Type 2423 Valve balanced by a bellows
H2
H
H1
ØD
L
Type 42-36, DN 15 to 250
Type 42-36 · Valve balanced by a bellows · Dimensions in mm and weights in kg
Nominal size DN 15 20 25 32 40 50 65 80 100 125 150 200 250
Length L 130 150 160 180 200 230 290 310 350 400 480 600 730
Height H1 225 300 355 460 590 730
Height H2 Other materials 115 135 195 220 265 295 400
1.4571 113 – 130 – 155 161 –
Height H 390 465 520 625 765 895
Actuator ∅D = 225 mm · A = 160 cm² 2) ∅D = 285 mm
A = 320 cm² 3)
Weight for PN 161) in kg 12 12.5 13.5 20 20.5 23 39 44 59 121 171 425 485
1) For valve in PN 25/PN 40: +10 %
2) Optionally also with actuator 320 cm² (DN 65 to 100).We recommend actuator 320 cm² for regulators
with double adapter (see T 3019 EN) in sizes DN 65 to DN 100.
3) Optionally also with actuator 640 cm²
Type 42-36 · Type 2423 Valve balanced by a bellows

EB 3015 EN 19
Dimensions
Fig. 10 · Dimensions and weights, Type 42-36 with Type 2423 Valve balanced by a diaphragm
Type 42-36 · Balanced by a diaphragm · Dimensions in mm and weights in kg
Nominal size DN 125 DN 150 DN 200 DN 250
Length L 400 480 600 730
Height H1 450 475 545
Height H2 295 325 345 375
Height H3 680 710 825
Weight for PN 161) in kg
Type 2423 Valve 65 85 250 270
Type 2426 Actuator 20 20 30 30
1) For valve in PN 25/PN 40: +10 %
H2
H1
L
Type 42-36, DN 125 to 250
Type 42-36 · Type 2423 Valve balanced by a diaphragm

SAMSON AG · MESS- UND REGELTECHNIK
Weismüllerstraße 3 · 60314 Frankfurt am Main · Germany
Phone: + 49 69 4009-0 · Fax: [phone]
Internet: http://www.samson.de EB 3015 EN
S/Z 2009-01