Samson 42-10 RS Service-Handbuch

Translation of original instructions

EB 3009 EN

Type42-10RS Check Valve (backow protection)

Self-operated Regulators

Edition April 2019

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.

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

Department (aftersalesser[email protected]).

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.samson.de > Service & Support > Downloads > Documentation.

Denition 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

2 EB 3009 EN

Contents

EB 3009 EN 3

1 General safety instructions.............................................................................4

2 Process medium and scope of application.......................................................5

2.1 Transportation and storage .............................................................................5

3 Design and principle of operation ..................................................................5

4 Installation....................................................................................................8

4.1 Mounting position ..........................................................................................8

4.2 Compensation chamber for steam ...................................................................8

4.3 Strainer .........................................................................................................9

4.4 Shut-off valve .................................................................................................9

4.5 Pressure gauge ..............................................................................................9

5 Operation.....................................................................................................9

5.1 Start-up .........................................................................................................9

5.1.1 Regulation of steam ......................................................................................10

5.1.2 Regulation of liquids .....................................................................................10

5.2 Set point adjustment .....................................................................................10

5.3 Decommissioning .........................................................................................10

6 Maintenance ...............................................................................................10

6.1 Tests ............................................................................................................12

7 After-sales service .......................................................................................12

8 Nameplates ................................................................................................13

9 Dimensions .................................................................................................14

10 Technical data.............................................................................................16

4 EB 3009 EN

General safety instructions

1 General safety instructions

−The device must be mounted, started up or serviced by fully trained and

qualied personnel only; the accepted industry codes and practices are to

be observed. Make sure employees or third persons are not exposed to any

danger.

−All safety instructions and warnings given in these mounting and operating

instructions, particularly those concerning installation, start-up, and mainte-

nance, must be strictly 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 dangers due to their specialized training, their

knowledge and experience as well as their knowledge of the applicable

standards.

−To ensure appropriate use, only use the device in applications where the op-

erating pressure and temperatures do not exceed the specications used for

sizing the device at the ordering stage.

−The manufacturer does not assume any responsibility for damage caused by

external forces or any other external factors.

−Any hazards that could be caused in the regulator by the process medium,

operating pressure or by moving parts are to be prevented by taking appro-

priate precautions.

−Proper transport, storage, installation, operation, and maintenance are as-

sumed.

Note: Non-electric control valve versions whose bodies are not lined with an in-

sulating material coating do not have their own potential ignition source accord-

ing to the risk assessment stipulated in EN13463-1: 2009, section5.2, even in

the rare incident of an operating fault. Therefore, such valve versions do not fall

within the scope of Directive 2014/34/EU.

For connection to the equipotential bonding system, observe the requirements

specied in section 6.3 of EN60079-14: 2011 (VDE0165 Part 1).

EB 3009 EN 5

Process medium and scope of application

2 Process medium and scope of

application

Designed to protect saturated steam, nitro-

gen and compressed air networks against

backow from directly connected systems.

−Differential pressure set point

Δp = 0.2bar · 0.3bar1)/3psi·5psi1)

−Valve sizes DN15 to 250/NPS½ to 10

−Pressure rating PN25·40/

Class150·300

−Compressed air and nitrogen up to

80°C·150°C2)/175°F·300°F2)

−Saturated steam with compensation

chamber up to 220°C/430°F

−Liquids up to 80°C/175°F

1) DN200 and 250/NPS8 and 10 version

2) Version with FKM diaphragm

2.1 Transportation and storage

The device must be carefully handled, trans-

ported and stored. Protect the regulator

against adverse inuences, such as dirt,

moisture or frost, during storage and trans-

portation.

When regulators are too heavy to be lifted

by hand, fasten the lifting sling to a suitable

place on the valve body.

Incorrectly attached lifting slings or supports.

Risk of injury and property damage due to

valve falling.

Securely fasten slings or supports to the

valve body and secure against slipping.

3 Design and principle of oper-

ation

See Fig.1 on page7.

The regulator prevents owback from directly

connected systems. Observe the pressure

and temperature limits on the nameplate.

The regulator is open, provided the upstream

pressure is at least 0.2bar/0.3psi greater

than the downstream pressure. It closes auto-

matically when the downstream pressure ris-

es to or above the value of the upstream

pressure.

The regulator basically consists of the valve

(1) with seat (2) and plug (3) as well as the

opening actuator (10) with two diaphragms

(11).

WARNING

6 EB 3009 EN

Design and principle of operation

The medium ows through the valve in the

direction indicated by the arrow. The posi-

tion of the valve plug (3) determines the dif-

ferential pressure over the cross-sectional ar-

ea released between the plug and seat (2).

At a differential pressure of

0.2bar/3.0bar1) (3psi/5psi)1), the valve

begins to open; at 0.35bar/0.55bar

(5psi/7psi), the valve is completely open.

At this point, the upstream pressure p1 must

be greater than the downstream pressure p2.

The regulator closes automatically when the

downstream pressure rises to or above the

value of the upstream pressure. The standard

plug is soft-seated to ensure tight shut-off

and to prevent backow from the plant into

the medium supply network.

The mounted control lines (14) transmit the

upstream and downstream pressures to the

actuator.

The actuator with two diaphragms (11)

offers increased safety and reliability of

functions. The operating diaphragm for

upstream pressure (11.1) is connected to the

valve input pressure, whereas the operating

diaphragm for downstream pressure (11.2)

is connected to the valve output pressure. A

bore with a mechanical diaphragm rupture

indicator (12) is located in the intermediate

ring located between the two diaphragms.

The pressure of response of the diaphragm

rupture indication is approximately

1.5bar/22psi. In the event of a diaphragm

rupture, the pressure in the space between

the two operating diaphragm starts to

1) DN200 and 250/NPS8 and 10 version

Legend Fig.1

1 Valve body

2 Seat

3 Plug

4 Plug stem

5Threaded connection for diaphragm

actuator

6Actuator stem

7 Diaphragm stem

10 Actuator housing

11 Two diaphragms

11.1 Operating diaphragm for upstream

pressure

11.2 Operating diaphragm for downstream

pressure

12 Diaphragm rupture indicator

13 Set point springs

14 Control line 8x1mm

15 Spacer bushing

16 Housing bolts (two long bolts opposite each

other, DN15 to 25/NPS½ to 1 only)

16.1 Top housing bolts

16.2 Bottom housing bolts

17 Diaphragm plate nut (outer)

17.1 Diaphragm plate nut (inner)

18 Pressure switch (optional)

19 Compensation chamber (optional)

20 Filler plug

increase. This causes the pin in the

diaphragm rupture indicator to be pushed

outwards and a red ring appears, indicating

the diaphragm rupture. The intact operating

diaphragm takes on the control task of the

ruptured diaphragm.

A pressure switch (18) can be optionally

mounted to the actuator to trigger an alarm.

EB 3009 EN 7

Design and principle of operation

Fig.1: Functional diagram·DN15 to 150/NPS½to 6

13.1

16.1

16.2

11.2

17.1

10.1

11.1

8 EB 3009 EN

Installation

4 Installation

See Fig.1 on page7.

Choose a place of installation that allows you

to freely access the regulator even after the

entire plant has been completed.

ÎInstall the regulator free of stress. If nec-

essary, support the pipeline near to the

connecting anges. Do not attach sup-

ports directly to the valve or actuator.

ÎInstall a strainer (e.g. SAMSON

Type2N/2NI) upstream of the regula-

tor to prevent any sealing parts, weld

spatter and other impurities carried

along by the process medium impairing

the proper functioning of the valve,

above all the tight shut-off.

4.1 Mounting position

The regulators are supplied ready for con-

nection.

ÎInstall the regulator in a horizontal pipe-

line.

1 Strainer

2 Type42-10RS Check

Valve (backow

protection)

3 Pressure gauge

4 Shut-off valve

p1Upstream pressure

p2Downstream pressure

Fig.2: Sample application

124

p1p2

ÎThe ow of direction must correspond

with the direction indicated by the arrow

on the valve body.

ÎDN15 to 150/NPS½ to 6: actuator

facing downward (see Fig.1 and

Fig.4).

DN200 to 250/NPS8 to 10: actuator

facing upward (see Fig.4).

Possible malfunction and damage due to ad-

verse weather conditions (temperature, hu-

midity).

Protect the regulator against frost if it is used

to control freezing media. Heat the regulator.

4.2 Compensation chamber for

steam

The mounting position of the compensation

chamber is indicated by an adhesive label

on the chamber itself as well as by an arrow

and the word "top" stamped on the top of

the chamber.

NOTICE

EB 3009 EN 9

Operation

This mounting position must be adhered to;

otherwise the safe functioning of the regula-

tor cannot be guaranteed.

4.3 Strainer

A strainer installed upstream in the ow pipe

holds back any dirt or other foreign particles

carried along by the medium. For example,

the SAMSON Type2N/2NI Strainer is suit-

able (uT1010).

ÎDo not use the strainer to permanently

lter the process medium.

ÎInstall a strainer upstream of the regula-

tor.

ÎThe ow of direction must correspond

with the direction indicated by the arrow

on the valve body.

ÎThe lter element must be installed to

hang downward.

Remember to leave enough space to remove

the lter element for cleaning.

4.4 Shut-off valve

Install a hand-operated shut-off valve both

upstream of the strainer and downstream of

the regulator (see Fig.2). This allows the

plant to be shut down for cleaning and

maintenance, and when the plant is not used

for longer periods of time.

Tip

4.5 Pressure gauge

Install a pressure gauge both upstream and

downstream of the regulator to monitor the

pressures prevailing in the plant.

5 Operation

5.1 Start-up

First start up the regulator after mounting all

parts.

ÎFor steam applications, make sure that

the pipelines are dry. Moisture will dam-

age the inside of the valve.

ÎEnsure that all valves downstream of the

regulator are open.

ÎOpen the shut-off valves preferably start-

ing from the downstream of valve. Slowly

open the valves in small steps waiting a

few minutes in between.

ÎRaise the plant pressure in steps of

5bar/70psi.

ÎWait several seconds after each rise in

pressure before continuing.

The test pressure must not exceed the nomi-

nal pressure of the valve by 1.5 times on test-

ing the pressure of the plant when the regu-

lator is already installed.

Note

NOTICE

10 EB 3009 EN

Maintenance

The pressure must not exceed the maximum

permissible constant operating pressure or

pressure acting on one side (see section10).

The lowest pressure always applies and re-

stricts the maximum test pressure.

5.1.1 Regulation of steam

ÎUnscrew ller plug (20, width across ats

13) on the compensation chamber. Use

the included plastic funnel or a jug to

pour in water until it starts to overow.

Screw the ller plug back in and tighten

it (25Nm). The regulator is now ready

for operation. Open the hand-operated

shut-off valves slowly to prevent water

hammer.

5.1.2 Regulation of liquids

ÎTo start up the regulator, open shut-off

valves slowly.

5.2 Set point adjustment

The user cannot adjust the set point.

The regulator is delivered with a ready ad-

justed set point of 0.2bar/3psi (DN15 to

150/NPS½ to 6) or 0.3bar/5psi (DN200

and 250/NPS8 and 10) and has been test-

ed.

The regulator is open, provided the upstream

pressure is greater than the downstream

pressure by at least the ready adjusted set

point. It closes automatically when the down-

stream pressure rises to or above the value

of the upstream pressure.

5.3 Decommissioning

Close the shut-off valves starting from the

ow pipe side.

6 Maintenance

The regulators do not require any mainte-

nance. Nevertheless, they are subject to nat-

ural wear, particularly at the seat, plug and

two diaphragms.

Depending on the operating conditions,

check the regulator regularly to detect and

rectify possible malfunctions at an early

stage.

If a diaphragm rupture is indicated and the

operating diaphragm is defective,

SAMSON's After-Sales Service department

can assist you.

Before performing any work on the regula-

tor, make sure the relevant plant section has

been depressurized and, depending on the

process medium, drained. We recommend

removing the valve from the pipeline.

Depending on the eld of application, allow

the valve to cool down or heat up to reach

ambient temperature before starting any

work on it.

Disconnect or shut off the control line.

As valves are not free of cavities, remember

that residual process medium might still be

contained in the valve.

Details on faults and how to remedy them

can be found in Table1.

WARNING

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