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1、Self-operated Pressure Regulators Pressure Reducing Valve Type 2405 Edition June 2010 Mounting and Operating Instructions EB 2520 EN Type 2405 Pressure Reducing Valve Contents 1Design and principle of operation . . . . . . . . . . . . . . . . . . . . . . 4 1.1Process medium and field of application
2、. . . . . . . . . . . . . . . . . . . 4 2Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 2.1Mounting positions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 2.2Strainer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 2.3Shut-off v
3、alve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 2.4Pressure gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 2.5Control line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 3Operation . . . . . . . . . . . . . . . . . . . . . . . . . .
4、. . . . . . . 6 3.1Start-up. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 3.2Set point adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 3.3Decommissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 4Maintenance and troubleshooting. . .
5、 . . . . . . . . . . . . . . . . . . . 9 4.1Pressure fluctuations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 5Nameplate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 6Customer service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 7Technical data. .
6、 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 8Dimensions and weights. . . . . . . . . . . . . . . . . . . . . . . . . . 12 2EB 2520 EN Contents WARNING! WARNING indicates a hazardous situation which, if not avoided, could result in death or serious injury. NOTICE NOTICEindicatesapro
7、pertydamage message. Note: Supplementary explanations, informa- tion and tips Definitions of the signal words used in these instructions EB 2520 EN3 Safety instructions General safety instructions ?The regulators must be installed, started up and serviced by fully trained and qualified personnel onl
8、y, 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. ?According to these Mounting
9、 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 applicable standards. ?The regulator complies wi
10、th 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 confor- mity assessment procedure. The declaration of conformity can be provided on request. ?For appropriate operati
11、on, make sure that the regulator is only used in ap- plications 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
12、 other external factors. ?Any hazards which could be caused in the regulator by the process medi- um or operating pressure are to be prevented by means of appropriate measures. ?Proper shipping and appropriate storage are assumed. Note: Non-electric valve versions which do not have a valve body line
13、d with an in- sulating coating do not have their own potential ignition source according to the ignition risk assessment stipulated in EN 13463-1: 2001, 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. 1Designandprincipl
14、eof operation See Fig. 1 on page 5. The medium flows through the valve in the di- rection indicated by the arrow. The position of the valve plug (3) determines the area released between the plug (3) and seat (2). In the idle position (control line not connected or no pressure applied), the valve is
15、opened by the force of the set point springs (7). The downstream pressure p2to be controlled is tapped downstream of the regulator using an external control line. This pressure is trans- ferred to the actuator housing (6) over the control line and is converted into a position- ing force by the diaph
16、ragm plate with operat- ing diaphragm (5). This force is used to move the plug stem (4) and the valve plug as a re- sult, depending on the force of the set point springs (7). The spring force can be adjusted at the set point adjuster (8). If the force resulting from the downstream pressure p2exceeds
17、 the spring force adjusted at the set point springs, the valve closes in proportion to the pressure change. In the version with pressure balancing, the forces at the plug caused by the upstream and downstream pressures are eliminated by the balancing diaphragm (10). The plug is fully balanced. 1.1Pr
18、ocess medium and field of application The Type 2405 Pressure Reducing Valves are only suitable for controlling gases in the tem- perature range between 20 and +60 C. 2Installation See Fig. 1 on page 5. NOTICE A strainer (SAMSON Type 2 NI) must be in- stalled upstream of the regulator (see sec- tion
19、2.2). 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. 2.1Mounting positions Standard installation preferable Install the valve in a horizon- tal pipeline. The actuator with set point ad
20、juster must face upwards. Make sure the medium flows through the valve in the direction indicated by the arrow. Install the control line to the tapping point with an approx. 10 % slope to allow any condensing liquid to flow back into the ves- sel (tank) or pipe. Other possible installations Install
21、the valve in a vertical pipeline. The actuator with set point adjuster must point to the side. Note: System deviations may occur in this mounting position. The medium must flow from the top of the valve downwards. 4EB 2520 EN Design and principle of operation EB 2520 EN5 Installation Fig. 1 Function
22、al diagrams p1 p2 8 12 7 6 5 11 4 9 1 3 2 Type 2405 without pressure balancing (KVS1.6 to 4) Flow-to-open 1Valve body 2Seat 3Plug 4Plug stem 5Diaphragm plate with operating diaphragm 6Actuator housing p1 p2 Type 2405 without pressure balancing (KVS0.1 to 1) Flow-to-close p1 10 Type 2405 with pressur
23、e balancing (KVS6.3 to 32) 7Set point spring(s) 8Set point adjuster (adjusting screw SW 27) 9Control line connection (G union for downstream pressure p2) 10Balancing diaphragm 11Venting plug or leak-off connection (special version) 12Cap 2.2Strainer The strainer must be installed upstream of the reg
24、ulator (Fig. 2). Make sure the direction of medium flow corresponds with the direction indicated by the arrow on the strainer. The fil- ter element must be suspended to hang down- wards. Remember to leave enough space to remove it. 2.3Shut-off valve Install a hand-operated shut-off valve both upstre
25、am of the strainer and downstream of the regulator (see Fig. 2). This allows the plant to be shut down for cleaning and mainte- nance and when the plant is not used for lon- ger periods of time. 2.4Pressure gauge To monitor the pressures in the plant, install a pressure gauge both upstream and down-
26、 stream of the regulator (see Fig. 2). 2.5Control line Connection G is located at the actuator housing. A control line with an inside diame- ter of min. 6 mm (preferably 8 x 1 mm, steel or stainless steel pipe) must be provided at the site of installation. The control line connection for pressure ta
27、p- ping must always be directly attached to the vessel (tank) because the medium is in the ex- panded state and no turbulence occurs at this point. If the pressure is to be tapped at a straight pipeline section, the largest possible distance to the regulator must be kept (at least 6 x DN). Connect t
28、he control line at the side or top of the horizontally running main pipeline. If pos- sible, place the point of pressure tapping in a pipe expansion. Install any pipe fittings (e.g. restrictions, bends, manifolds or branches), that may cause turbulence in the flow, sufficiently far away from the pre
29、ssure tapping points (at least 6 x DN). Note: If the gas to be controlled is damp, con- densate may collect in the control line which could damage the controller. Install the con- trol line with an approx. 10 % slope to the pressure tapping point in the vessel (tank) or pipe to allow the condensate
30、to flow back into the vessel. 3Operation 3.1Start-up NOTICE First start up the regulator after mounting all the components. The control line must be free of dirt and the flow cross-section must be open. Make sure the control line is correctly con- nected. Open the shut-off valves slowly preferably s
31、tarting from the return flow pipe side. Avoid pressure surges (hammering). 6EB 2520 EN Installation EB 2520 EN7 Operation Fig. 2 Typical installations min. 6 x DN min. 12 x DN DN 221 p1 1 211 p1p2 3 3 24 4 p2 min. 3 x DN 1Shut-off valve 2Pressure gauge 3Strainer 4Control line Type 2405 Type 2405 10
32、% slope to pressure tapping point 10 % slope to pressure tapping point NOTICE When testing the pressure of the plant with the regulator already installed, the nominal pressure (body) is permissible (see section 7). However, it is important that the maximum permissible pressure at the operating diaph
33、ragm is not exceeded. If this cannot be guaranteed, proceed as follows: Unscrew the control line at the actuator and seal the open control line. If pressure surges are to be expected during start-up or during operation, use a regulator with integrated force limiter (special version). See section 7 f
34、or pressure limits. All plant components must be sized for the test pressure. 3.2Set point adjustment See Fig. 1 on page 5. Adjust the required set point by tensioning the set point springs (7) at the set point adjuster (8). ?Remove cap (12). ?Use a socket wrench (SW 27) to turn the screw (8). ?Turn
35、 it clockwise to increase the set point pressure and counterclockwise to reduce the set point pressure. ?Screw back on cap (12). The pressure gauge (Fig. 2) installed on the downstream side on site allows the adjusted set point to be monitored. 3.3Decommissioning Close first the shut-off valve on th
36、e upstream side and then on the downstream side. 8EB 2520 EN Operation Fig. 3 Set point adjustment (view from above) Screw SW 27 (3/4”) 4Maintenanceandtrouble- shooting The regulators are maintenance free. Never- theless, they are subject to natural wear, par- ticularly at the seat, plug and operati
37、ng dia- phragm. Depending on the operating conditions, the regulator needs to be checked at regular in- tervals to avoid possible malfunctions. WARNING! On performing any work on the regulator, make sure the relevant section of the pipeline is depressurized and, depending on the pro- cess medium, dr
38、ained as well. We recommend to remove the valve from the pipeline. 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 fre
39、e of cavities, remember that residual process medium might still be contained in the valve. 4.1Pressure fluctuations NOTICE Pressure fluctuations (oscillations) could dam- age the regulator and plant. Therefore, they should not be allowed to occur or the reason for their occurrence must promptly be
40、elimi- nated. To eliminate any oscillations, the following measures may be helpful: ?Check the pressure tapping of the con- trol line (see section 2.5). If need be, relocate the point of tapping. ?Screw SAMSON Venturi nozzle into the union for the control line connection (9) (item no. 1991-7114 for
41、1200/640 cm or item no. 1991-7113 for 320/160 cm). ?Check the sizing data used for the regu- lator. If necessary, change the KVS coefficient, seat diameter or diaphragm area. If faults cannot be remedied, contact SAM- SONs After-Sales Service (see section 6). EB 2520 EN9 Maintenance and troubleshoot
42、ing 5Nameplate 6Customer service Should any malfunctions or any defect occur, SAMSONs 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 cente
43、rs 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): ?Type and nominal size of the valve ?Configuration ID (Var.-ID) ?Upstream and dow
44、nstream pressure ?Temperature and control medium ?Minimum and maximum flow rate ?Has a strainer been installed? ?Sketch of the installation with exact position of regulator and all additional installed components (shut-off valves, pressure gauges, etc.). 10EB 2520 EN Nameplate Fig. 4 Nameplate 6Nomi
45、nal size DN 7Nominal pressure (body) 8Max. inlet pressure (max. perm. pressure at the operating diaphragm) 9Perm. temperature 10 Body material 23 56 1 SAMSON 4 2009 78910 Explanations 1Type designation (2405) 2Configuration ID (Var.-ID) 3Order number or order date 4KVScoefficient 5Set point range 7T
46、echnical data EB 2520 EN11 Technical data Table 1 Technical data Nominal sizeDN 15 to 25DN 32 to 50 Nominal pressure (body)PN 16 PN 25 PN 40 KVScoefficients 0.1 0.25 0.4 1 1.6 2.5 4 6.3 8 6.3 8 16 20 32 Max. perm. upstream pressure10 bar 12 bar1) Max. perm. temperature range (medium temperature)20 t
47、o +60 C 2) Leakage class acc. to IEC 60534-4Soft-seated, minimum class IV Set point ranges3) 5 to 15 mbar 10 to 30 mbar 25 to 60 mbar 50 to 200 mbar 0.1 to 0.6 bar 0.2 to 1 bar 0.8 to 2.5 bar 2 to 5 bar Max. perm. pressure at the operating diaphragm 1200 cm 5 to 15 mbar 10 to 30 mbar1 bar 640 cm 10
48、to 30 mbar 25 to 60 mbar4 bar (KVS= 0.1 to 1) 2 bar (KVS= 1.6 to 32) 320 cm 25 to 60 mbar 50 to 200 mbar8 bar (KVS= 0.1 to 1) 4 bar (KVS= 1.6 to 32) 320 cm 0.1 to 0.6 bar1.5 bar 10 bar4) 160 cm 0.2 to 1 bar2.5 bar 20 bar4) 80 cm 0.8 to 2.5 bar5 bar 20 bar4) 40 cm 2 to 5 bar10 bar 20 bar4) Pressure b
49、alancing KVS= 0.1 to 4Without balancing diaphragm KVS= 6.3 to 32With balancing diaphragm Pressure tappingExternal control line Control line connection (threaded union)G 1)Version with set points from 0.1 to 5 bar 2)Higher and lower temperatures on request 3)Higher set point ranges on request 4)Version with force limiter 8Dimensions and weights 12EB 2520 EN Dimensions and weights Fig. 5 Dimensions DN 15 to 25 DN 32 to 50 EB 2520 EN13 Dimensions and weights Table 2 Dimensions in mm and weights in kg Nom