Samson 46-5 Service manual

Differential Pressure Regulators
with Flow Limitation
Type 46-5
Type 46-6
Mounting and
Operating Instructions
EB 3130 EN
Edition February 2010Edition February 2010
Type 46-6
Type 46-5

Contents Page
1 Design and principle of operation . . . . . . . . . . . . . . . . . . . 4
2 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2.1 Mounting position . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2.2 Control line. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2.3 Strainer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2.4 Shut-off valves, pressure gauges. . . . . . . . . . . . . . . . . . . . . 7
3 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
3.1 Start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
3.2 Set point adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . 8
3.3 Differential pressure set point . . . . . . . . . . . . . . . . . . . . . . 8
3.3.1 Setting the differential pressure . . . . . . . . . . . . . . . . . . . . . 8
3.4 Adjusting the flow rate limit . . . . . . . . . . . . . . . . . . . . . . . 9
3.4.1 Plant pressure drop known. . . . . . . . . . . . . . . . . . . . . . . 10
3.4.2 Plant pressure drop not known . . . . . . . . . . . . . . . . . . . . . 10
3.5 Decommissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
3.5.1 Pressure conditions in the plant and at the regulator. . . . . . . . . . . 12
4 Maintenance – Replacing parts . . . . . . . . . . . . . . . . . . . . 16
4.1 Cleaning or replacing the plug. . . . . . . . . . . . . . . . . . . . . 16
4.2 Replacing the diaphragm . . . . . . . . . . . . . . . . . . . . . . . 16
5Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
6 Nameplate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
7 Customer inquiries . . . . . . . . . . . . . . . . . . . . . . . . . . 19
8 Dimensions and weights . . . . . . . . . . . . . . . . . . . . . . . 20
9 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
2EB 3130 EN
Contents
WARNING!
WARNING indicates a hazardous situation
which, if not avoided, could result in death or
serious injury.
NOTICE
NOTICE indicates a property damage
message.
Note: Supplementary explanations, informa-
tion and tips
Definitions of the signal words used in these instructions

Note:
Non-electric control valves, whose valve bodies are not lined with an insulating material
coating, do not have their own potential ignition source according to the ignition risk assess-
ment stipulated in EN 13463-1: 2001, section 5.2, even in the rare incident of an operating
fault. Therefore, such valve versions do not fall within the scope of Directive 94/9/EC.
Safety instructions
EB 3130 EN 3
General safety instructions
4
The regulators may only 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.
All safety instructions and warnings in these instructions, particularly those
concerning installation, start-up and maintenance, must be observed.
4
According to these mounting and operating instructions, trained personnel is
referred to as individuals who are able to judge the work they are assigned
to and recognize possible dangers due to their specialized training, their
knowledge and experience as well as their knowledge of the relevant stan-
dards.
4
The regulator complies with the requirements of the European Pressure
Equipment Directive 97/23/EC. The declaration of conformity issued for a
regulator bearing the CE marking includes information on the applied
conformity assessment procedure and will be provided on request.
4
To ensure appropriate use, only use the regulator in applications where the
operating pressure and temperatures do not exceed the operating values
specified in the order.
4
Note that the manufacturer does not assume any responsibility for damage
caused by external forces or any other external factors.
Take appropriate safety precautions to prevent hazards that may be caused
in the regulator by the process medium, operating pressure, or moving parts.
4
Make sure the regulator is shipped and stored properly.

1 Design and principle of
operation
The regulators basically consist of a valve (1)
with orifice (1.2) and balanced plug (3) as
well as a closing actuator with an operating
diaphragm (6.1). In Type 46-5, the valve
springs (5) integrated in the valve body de-
termine the set point. In Type 46-6, the set
point can be adjusted by the set point
spring(s) on the actuator.
The regulators are used to limit the differen-
tial pressure and flow rate to the set points
adjusted. As the differential pressure (flow
rate) increases, the valve closes. The medium
flows through the valve in the direction indi-
cated by the arrow. The flow rate and the
differential pressure are determined by the
free area available between the orifice (1.2)
and plug (3). The high pressure of the plant
is transmitted to the diaphragm (6.1) over an
externally routed control line (11). The pres-
sure downstream of the orifice (1.2) is trans-
mitted over a hole in the plug to the
low-pressure side of the operating dia-
phragm. The resulting differential pressure is
converted into a positioning force at the dia-
phragm. This force moves the plug depend-
ing on the force of the valve spring (5) or set
point spring(s) (8). The maximum flow rate
(flow limitation) is adjusted at the orifice
(1.2). The cross-section of the valve is
changed in such a way that the differential
pressure and the differential pressure created
at the restriction (orifice) are identical when
the required maximum flow rate exists.
4EB 3130 EN
Design and principle of operation
Δp
1
17
16
18
1.2
2
3
4
5
6
11
6.3
6.1
15
6.4
Fig. 1 · Sectional diagram
Type 46-5 · Flanged body
1 Valve body
1.1 Connection nut
1.2 Orifice
2 Seat
3 Guide nipple with plug section
4 Plug stem
5 Valve spring(s)
6 Actuator
6.1 Operating diaphragm with
diaphragm plate
6.2 Actuator stem
6.3 Nut
6.4 Excess pressure limiter
(internal overload protection)
8 Set point spring(s)
9 Spring plate
10 Set point adjuster
11 Control line (high-pressure side)
15 Screws
16 Lock nut
17 Set point screw for flow rate (SW 4)
18 Cap
19 Manual adjuster
20 Spindle
21 Support
Turned into the
plane of projection

EB 3130 EN 5
Design and principle of operation
Fig. 2 · Sectional drawings
Type 46-6 · Version with manual adjuster
DN 15 to 32 · Δset point range 0.2 to 1 bar
6.1
15
6.4
6.3
6
9
20
21
19
11
Δp
11
6.3 2
3
4
6.4
17
16
18
5
15
6.1
Δp
6
6.2
9
10
8
1
1.2
1.1
Type 46-6 · Screwed ends
11
6.3
2
3
17
16
18
6.4 5
4
6.1
15
Δp
6
1
1.2
1.1
Type 46-5 · Screwed ends
Turned into the
plane of projection
Turned into the
plane of
projection
Turned into the
plane of projection
Position DN Nm
Pos. 3 · Guide nipple 15 to 25
32 to 50 70 110
Pos. 15 · Screws 15 to 32
40 to 50 8 18
Table 1 · Tightening torques in Nm

An internal overload protection (excess pres-
sure limiter) (6.4) in the actuator protects seat
and plug from overload during exceptional
operating conditions that could lead to valve
or plant damage.
2 Installation
The regulators are mainly installed in the
low-pressure line, e.g. return flow pipe of the
plant.
In district heating plants, the regulators must
be installed in the return flow pipes only (see
Fig. 3).
2.1 Mounting position
Install the regulator in horizontal
pipelines with the actuator sus-
pended downwards.
For valve sizes DN 15 to 25, the
regulator can also be installed in
vertical pipelines.
The following points must be observed:
–The medium must flow through the valve in
the direction indicated by the arrow on the
valve body.
–Connect external control lines at the side of
the main pipe (see Fig. 4)
–Install a strainer (e.g. SAMSON Type 1 FN
Strainer) upstream of the valve, e.g. up-
stream of the transfer station.
NOTICE
Protect the regulator against frost when con-
trolling freezing media.
2.2 Control line
Depending on the regulator version, a con-
trol line (standard: 6 mm pipe diameter) must
be adapted and mounted on site. Make sure
that the control line is free of dirt.
The control line for tapping pressure from the
pipeline must be installed at least 3 x DN
away from any pipe fittings (e.g. restrictions,
bends or branches), that may cause turbu-
lence in the flow (Fig. 4.1). How the lines are
routed generally depends on the installation
location. Preferably connect the control line
to the side of the main pipe (Fig. 4.4).
Do not change the pipe diameter of the main
pipeline so that it is off-center!
6EB 3130 EN
Installation
_
+
Fig. 3 · Typical installation (schematic)
- - - - - Fixed network connection to the actuator
= = = = To be installed while mounting the regulator
p1
p2
Δpmin

Refer to installation schematics (Fig. 3) for
line routing.
2.3 Strainer
Install a strainer (e.g. SAMSON Type 1FN)
upstream of the regulator to prevent sealing
particles, weld spatter, pipe scale and other
impurities carried along by the process me-
dium from impairing the proper operation,
especially the tight shut-off of the valve.
Make sure that the medium flow corresponds
with the direction indicated by the arrow on
the strainer body.
Install the strainer with the filter element sus-
pended downward. Ensure that ample space
is available to remove the filter.
2.4 Shut-off valves, pressure
gauges
Ideally, install hand-operated shut-off valves
both upstream of the strainer and down-
stream of the differential pressure regulator.
This allows the plant to be shut down for
cleaning and maintenance routines, or when
the plant is not operated for long periods of
time.
To monitor the pressures prevailing in the
plant, install pressure gauges both upstream
and downstream of the regulator and in the
flow and return flow pipes at the pressure
tapping points.
EB 3130 EN 7
Installation
Fig. 4 · Control line connection
4.3 · Connection at the top – incorrect
4.2 · Connection at the bottom – incorrect
Incorrect!
Incorrect!
MDN
min.
3 x DN
min.
3 x DN
min.
3 x DN
4.1 · Control line connection, depending on
how the pipeline is routed
DN = Nominal size
4.4 · Connection at the side – correct
Correct!

3 Operation
3.1 Start-up
WARNING!
First start up the regulator after mounting all
the components.
Make sure the control lines are free of dirt
and their cross-section open. Prior to
start-up, check to ensure the control lines are
connected correctly.
Note: On filling the plant, the orifice (1.2)
must be open by turning the set point screw
(17) counterclockwise as far as it will go.
4Open all valves on the consumer side.
Open the shut-off valves slowly prefera-
bly starting from the return flow pipe side.
Rinsing the plant · After filling the plant, first
completely open the consumers. Set the max-
imum flow cross-section (by turning the set
point screw counterclockwise as far as it will
go) and the maximum differential pressure
(by tensioning the set point spring). Rinse out
the pipeline at full flow rate for several min-
utes. Then check the installed strainer (e.g.
by measuring the pressure drop). Clean the
strainer, if necessary.
NOTICE
When pressure-testing the pipelines with the
regulator installed, make sure the test pres-
sure does not exceed 1.5 times the nominal
pressure.
The orifice to adjust the flow rate at the regu-
lator must be completely open.
If necessary, remove the regulator from the
pipeline.
All plant components must be sized for the
test pressure.
3.2 Set point adjustment
The following generally applies: First adjust
the differential pressure set point and then
the flow limitation.
3.3 Differential pressure set point
3.3.1 Setting the differential
pressure
Type 46-6 only
Adjust the desired differential pressure at the
set point adjuster (10) or manual adjuster
(19) with the plant almost shut and with fully
open orifice (1.2). First afterwards adjust the
limit value for the flow rate.
Set point adjuster (10) or manual adjuster
(19)
–Turn it clockwise to load the springs →The
set point increases.
–Turn it counterclockwise to relieve the spring
tension →The set point is reduced.
8EB 3130 EN
Operation

How to proceed
4Close the motorized valve.
4Unscrew the cap (1.3) and undo lock nut
(1.2).
4Open the orifice so that the flow restric-
tion does not take effect: First turn the set
point screw (17) counterclockwise as far
as it will go to open the orifice (1.2)
4Slightly open the motorized valve
(approx. 10 % travel).
4Adjust the differential pressure by turning
the set point adjuster (10) to load the set
point springs (8). Refer to section 3.5.1.
For the set point range from 0.2 to 1 bar
(DN 15 to 32), the set point spring is in-
stalled in the bottom section of the valve
body. In this case, the set point can be di-
rectly adjusted at the manual adjuster (19)
according to the scale. One turn of the man-
ual adjuster will change the differential pres-
sure by 0.033 bar.
NOTICE
Do not adjust the set point to a scale value
smaller than 1!
Under certain conditions, the set point can-
not be adjusted anymore as a result.
In this case, the following action is recom-
mended:
– Relieve the process pressure from both
sides of the regulator.
– Turn the adjuster counterclockwise as far
as it will go to its lowest position.
– Turn the adjuster back clockwise at least
past the scale value 1 to 2.
– The regulator can now be readjusted.
3.4 Adjusting the flow rate limit
To achieve the maximum flow rate, all con-
trol and shut-off valves as well as all consum-
ers including the motorized valve must be
open (to ensure minimum drag in the plant).
If a bypass is installed in the plant, it must be
closed.
Note: Set point adjustment is always based
on a closed orifice (1.2).
Set point screw (17)
Hexagon socket SW 4:
–Turn it clockwise to close the orifice →Flow
rate decreases.
–Turn it counterclockwise to open the orifice
→Flow rate increases.
EB 3130 EN 9
Operation
0
0.2
0.4
0.6
0.8
1
1.2
123456
Fig. 5 · Adjustment diagram (DN 15 to DN 32)

3.4.1 Plant pressure drop known
To adjust the flow rate limit when the pres-
sure drop of the plant is known, use the ad-
justment diagrams (Fig. 7 to 9).
How to proceed
4Unscrew the cap (18).
4Undo lock nut (16) and turn the set point
screw (17) clockwise as far as it will go to
close the orifice.
4Adjust the flow rate according to the
value found (number of turns in counter-
clockwise direction).
4Secure orifice setting using the lock nut
(16) at the set point screw (17). Screw
cap (18) back on.
4Lead-seal set point setting at set point
screw (17) and cap (18).
For special versions with a scaled cap, the
limit value can be adjusted directly (one
scale division corresponds to one turn of the
set point screw (17).
Note: To determine the flow limitation to be
adjusted, and for Type 46-6 additionally the
differential pressure required, the differential
pressure across the orifice must be added to
the known pressure drop of the plant. From
experience, the differential pressure at the re-
striction (orifice) is assumed to be 0.2 bar.
The curves of the flow ranges in the dia-
grams on the following pages apply to this
assumed value.
3.4.2 Plant pressure drop not
known
How to proceed
4Unscrew the cap (18).
4Undo lock nut (16) and turn the set point
screw (17) clockwise as far as it will go to
close the orifice.
4Completely open the motorized valve.
4Open the orifice initially one turn at a
time. Check the flow rate at the heat me-
ter (reading of flow measuring unit). Then
adjust it in smaller steps until the required
flow rate is constant (±2 % deviations are
generally acceptable).
4If the maxiumum flow rate is not reached,
the differential pressure set point (in Type
46-6) must be increased. See section 3.3.
4After reaching the required flow rate,
secure orifice setting using the lock nut
(16). Screw cap (18) back on.
4Lead-seal set point setting at set point
screw (17) and cap (18).
Example: Adjusting the flow limitation when
pressure loss across the plant is known
Determine the adjusting values using the ad-
justment diagram (Fig. 7) for DN 15 (50, 25)
with Kvs = 0.4 to 1.
In a Type 46-6 Regulator, DN 15, Kvs = 1,
the flow rate is to be limited to 0.63 m³/h.
The pressure drop across the plant is
0.4 bar.
What is the limit value of the flow rate set
point and how many turns of the set point
screw are necessary?
10 EB 3130 EN
Operation