Samson 45-6 User manual

Differential Pressure Regulator
Type 45-6
Mounting and
Operating Instructions
EB 3 26 EN
Edition January 2004
Fig. 1 ⋅Type 45-6

Contents Page
1 Design and principle of operation . . . . . . . . . . . . . . . . . . . . . . 4
2 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2.1 Installation position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2.2 Strainer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2.3 Shut-off valves, pressure gauges . . . . . . . . . . . . . . . . . . . . . . . 5
3Operation
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
3.1 Start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
3.2 Set point adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
4 Maintenance  Replacement . . . . . . . . . . . . . . . . . . . . . . . . . 6
4.1 leaning or replacing the plug . . . . . . . . . . . . . . . . . . . . . . . . 7
4.2 Replacing the diaphragm . . . . . . . . . . . . . . . . . . . . . . . . . . 7
5 Troubles ooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
6 Description of t e nameplate . . . . . . . . . . . . . . . . . . . . . . . . . 9
7 Customer inquiries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
8 Dimensions and weig ts . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Contents
2EB 3126 EN

General safety instructions
General safety instructions
Only fully trained and qualified personnel may mount, start up, and service
the device, o serving the accepted industry codes and practices. Make sure
employees or third persons are not exposed to any danger.
All safety instructions and warnings in these instructions, particularly those
concerning installation, start-up, and maintenance, must e strictly o served.
The regulator fulfills the requirements of the European Pressure Equipment Di-
rective 97/23/EC. Valves with a CE marking have a declaration of conform-
ity that includes information on the applied conformity assessment procedure.
The declaration of conformity can e viewed and downloaded on the Internet
at http://www.samson.de.
For appropriate operation, make sure that the regulator is only used in appli-
cations where the operating pressure and temperatures do not exceed the op-
erating values ased on the valve sizing data su mitted in the order.
Note that the manufacturer does not assume any responsi ility for damage
caused y external forces or any other external influences.
Any hazards which could e caused in the regulator y the process medium,
the operating pressure, or moving parts are to e prevented y means of ap-
propriate measures.
Proper shipping and appropriate storage are assumed.
Caution!
Prior to removing the regulator from the pipeline, always depressurize the rele-
vant section of the plant and drain the pipeline if the process medium is a
liquid. If necessary, allow the regulator to cool down or heat up to reach am-
ient temperature prior to starting any work on the regulator.
Protect the regulator against frost when controlling freezing media.
Note! Non-electrical control valves, whose valve odies are not lined with an
insulating material coating, do not have their own potential ignition source
according to the risk assessment stipulated in EN 13463-1: 2001, paragraph
5.2, even in the rare incident of an operating fault. Therefore, such valve ver-
sions do not fall within the scope of Directive 94/9/EC.
EB 3126 EN 3

1 Design and principle of operation
The differential pressure regulator consists
of a valve with a balanced plug and of an
opening actuator with an operating dia-
phragm and a spring assembly.
The differential pressure regulator is de-
signed to maintain the differential pressure
at the adjusted set point.
The valve opens as the differential pressure
rises. The medium flows through the valve in
the direction indicated by the arrow. The
pressure in the valve outlet (low pressure),
transmitted via the attached control line
(10), acts on the lower diaphragm cham-
ber. The high pressure, transmitted through
Fig. 2 ⋅Sectional drawing
1Valve body
2Seat
3Plug
4Nut
5Diaphragm plate
6 Operating diaphragm
7Screws
8 Positioning spring(s)
9 Set point adjuster
10 ontrol line
11 Bore
1
2
3
4
5
6
7
8
9
10 11
Tightening torques
DN Nm
Item 3 Plug 15...25
32...50
70
110
Item 4 Nut 15...25
32...50
25
45
Item 7 Screws 15...32
40...50
8
18
4EB 3126 EN
Design and principle of operation

the bore (11) in the valve body, acts on the
upper diaphragm chamber of the actuator.
The differential pressure creates a position-
ing force at the operating diaphragm which
is used to position the plug depending on
the force of the positioning springs (8). The
force of the spring assembly, i.e. the set
point, is modified by turning the set point
adjuster (9).
2Installation
2.1 Installation position
The differential pressure regulators must be
installed in horizontal bypass or short-cir-
cuit pipes with the actuator suspended
downward (see Fig. 3).
Regulators in sizes DN 15 to DN 25 can be
installed in vertical pipelines, too. For me-
dium temperatures above 80 ° , the regulator
must not be installed with the diaphragm actu-
ator pointing vertically upward. The medium
must flow through the valve in the direction in-
dicated by the arrow on the valve body.
2.2 Strainer
Since sealing parts, globules, and other im-
purities carried along by the medium may
impair the proper functioning of the valve
and especially the tight shut-off, a strainer
(SAMSON Type 1NI) must be installed up-
stream of the differential pressure regulator.
The strainer must be installed so that the me-
dium flows through it in the direction indi-
cated by the arrow on the strainer body.
The filter element must be suspended down-
ward. Ensure that there is sufficient space
available to remove the filter.
2.3 S ut-off valves, pressure
gauges
We recommend the installation of hand-
operated shut-off valves both upstream of
the strainer and downstream of the regula-
tor. This allows the plant to be shut down
for cleaning and maintenance routines or
when it is not operated for extended
periods.
Install pressure gauges upstream and down-
stream of the valve to monitor the pressures
prevailing in the plant.
Fig. 3 ⋅Installation examples
1Shut-off valve
2Strainer
3Regulator
4 Pressure gauge
1
32
4
+
–
+
–
1
23
4
1
+–
Installation in a short-circuit pipe
Installation in a bypass pipe
EB 3126 EN 5
Installation

3Operation
3.1 Start-up
Fill the plant very slowly on start-up.
When pressure-testing the pipelines with the
regulator installed, make sure the test pres-
sure does not exceed 1.5 times the nominal
pressure.
3.2 Set point adjustment
The required differential pressure is ad-
justed at the set point adjuster (9) which
loads the spring(s).
Turn the set point adjuster clockwise to
increase the differential pressure.
Turn the set point adjuster counterclock-
wise to reduce the differential pressure.
4 Maintenance  Replacement
The regulator is maintenance-free, but is
subject to wear and tear, especially at the
seat, plug, and operating diaphragm. De-
pending on the application conditions that
prevail, the regulator must be inspected at
appropriately scheduled intervals to prevent
any problems before they occur. Details on
faults and how to correct them can be found
in the table on page 8. If a problem cannot
be solved with the help of the information
specified in the table, contact SAMSON.
In order to replace the plug and operating
diaphragm, proceed as described in sections
4.1 and 4.2.
Caution
If you intend to carry out any work
on the differential pressure regula-
tor, you are required to remove the
device from the pipeline. For this
purpose, first allow the relevant sec-
tion of the plant to cool down in
case of high temperatures. Then,
depressurize and drain this section
prior to removing the regulator.
6EB 3126 EN
Operation

4.1 Cleaning or replacing t e plug
1. Disassemble springs (8).
Caution!
The springs are pre-loaded. Take proper
precautionary measures or, if necessary,
make a disassem ly tool.
2. Unscrew the control line (10).
3. Loosen screws (7) and lift off actuator.
4. For valve sizes DN 15 to 25, unscrew
and remove the guide nipple with plug
(3) using a socket wrench (order no.
1280-3001).
The wrench can be made, for example,
from a Gedore screwdriver bit (IN 19-
19) by boring a 17 mm hole with a 17
mm diameter into the 19 mm hexagon
bit.
For valve sizes DN 32 to 50, first
remove the stopper and then pull out
the plug.
5. lean seat and plug thoroughly. heck
control line and screw connections and
bore (11) for any blockages.
Should the plug be damaged, replace
the entire plug.
To reassemble the regulator, proceed in
reverse order.
Make sure that the diaphragm is inserted
properly in the body groove before fasten-
ing the components.
Refer to tightening torques listed in the table
in Fig. 2.
4.2 Replacing t e diap ragm
1. Disassemble springs (8).
Caution!
The springs are pre-loaded. Take proper
precautionary measures or, if necessary,
make a disassem ly tool.
2. Unscrew control line (10).
3. Loosen screws (7) and lift off actuator.
4. Unscrew nut (4) sealed with paint while
holding lower nut stationary.
5. Lift off diaphragm plate and replace
diaphragm.
6. To reassemble, proceed in reverse
order.
Make sure that the diaphragm is in-
serted properly in the body groove be-
fore fastening the components.
Refer to tightening torques listed in the
table in Fig. 2.
Fig. 4 ⋅Socket wrench
17
Ø 17
SW 19
19 mm hexagon bit
EB 3126 EN
Maintenance  Replacement

5 Troubles ooting
Fault Possible cause Solution
Differential
pressure set
point is
exceeded
Valve too large for
control task
Recalculate the valve sizing flow coefficient,
KVS, and contact SAMSON.
Seat and plug untight Remove valve, clean seat and plug. If
necessary, replace plug (section 4.1).
Otherwise, return device for repair.
Operating diaphragm
defective
Replace diaphragm (section 4.2) or return the
device to SAMSON for repair.
ontrol line plugged Remove control line and clean it.
Differential
pressure set
point is not
reached
Valve too small for
control task
heck set point range and contact SAMSON.
Safety device, e.g.
pressure limiter, has
been triggered
heck plant, unlock safety device.
Insufficient pressure
drop across the plant
ompare existing differential pressure in the
plant with the plants drag.
Strainer blocked Drain and clean filter of the strainer.
Wrong installation of
valve
Reinstall the valve in such a way that the
medium flows through the valve in the
direction indicated by the arrow.
ontrol loop
hunts
Valve too large for
control task
Recalculate the valve sizing flow coefficient,
KVS, and contact SAMSON.
8EB 3126 EN
Troubleshooting

6 Description of t e nameplate 7 Customer inquiries
In case of inquiries, please submit the follow-
ing details:
Regulator type and nominal size
Thread or flange connection
Model number
Upstream and downstream pressures
Flow rate in m3/h
Has a strainer been installed?
Installation diagram
Fig. 5 ⋅La eling
.
1
4
23
1Model number
2Index
3Date
4Type designation
In the other fields:
Nominal pressure PN or ANSI lass
K
85
or
8
coefficient
Max. perm. temperature ° or °F
Set point range: differential pressure in bar
or psi
Max. perm. differential pressure ∆p
EB 3126 EN 9
Description of the nameplate

8 Dimensions and weig ts
L1
L
SW
G
Rd
ØD
H
H1
?
L3 L3
L
L2
L
A
SW
onnection nuts with
flanges Flanged body DN 40 and 50
onnection nuts with
threaded ends
onnection nuts with
weld-on fittings
10 EB 3126 EN
Dimensions and weights

Nominal size DN 152025324050
Inside pipe diameter d 21.3 26.8 32.7 42 48 60
onnection D G 3/4 G 1 G 1 1/4 G 1 3/4 G 2 G 2 1/2
Width across flats SW 303646596582
Length L 65 70 75 100 110 130
Height H 32 45 45
Height H1 240 260 405
Height H2 160 180 -
Height H3 85 105 140
Diameter D 116 160
Weld-on fittings L1 210 234 244 268 294 330
Weight appr. kg 2.0 2.1 2.2 8.5 9 9.5
Special version with threaded ends (male thread)
Length L2 129 144 159 180 196 228
Male thread A G 1/2 G 3/4 G 1 G 1 1/4 G 1 1/2 G 2
Weight appr. kg 2.0 2.1 2.2 8.5 9 9.5
Special version with flanges PN 16/25 or version with flanged body (DN 40/50)
Length L3 130 150 160 180 200 230
Weight appr. kg 3.4 4.1 4.7 11.7 13 14.5
EB 3126 EN 11
Dimensions and weights

SAMSON AG ⋅ MESS- UND REGELTE HNIK
Weismüllerstraße 3 ⋅ 60314 Frankfurt am Main ⋅ Germany
Phone: [phone] ⋅ Fax: [phone]
Internet: http://www.samson.de EB 3126 EN
S/Z 2004-01