Mounting and Operating Instructions EB 3017 EN. Self-operated Regulators

Transcription

1 Self-operated Regulars Flow and Differential Pressure Regular Type Flow and Differential Pressure or Flow and Pressure Regular Type Type Type Fig. 1 Flow and differential pressure or pressure regulars Mounting and Operating Instructions EB 3017 EN Edition September 2008

2 Contents Contents Page 1 Design and principle of operation Installation Mounting position Control line, equalizing tank and needle valve Strainer Shut-off valve Pressure gauge Operation Start-up Set point adjustment Set point for flow rate Set point for differential pressure Pressure set point in Type Flow and Pressure Regular Decommissioning Cusmer service Maintenance Troubleshooting Nameplates Technical data Dimensions Definitions of the signal words used in these instructions CAUTION! indicates a hazardous situation which, if not avoided, may result in injury. Note: Supplementary explanations, information and tips NOTICE indicates a property damage message. 2 EB 3017 EN

3 Safety instructions General safety instructions The regulars 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 any danger. The regular 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. For appropriate operation, make sure that the regular 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 facrs. Any hazards which could be caused in the regular by the process medium or operating pressure are be prevented by means of appropriate measures. Proper shipping and appropriate srage 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 the ignition risk assessment stipulated in EN : 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 the equipotential bonding system, observe the requirements specified in section 6.3 of EN : 2003 (VDE 0165 Part 1). EB 3017 EN 3

4 Design and principle of operation 1 Design and principle of operation The regulars limit the flow rate in the pipeline. The set point for the flow rate is adjusted at the restriction and the set point for the differential pressure or the downstream pressure is adjusted at the actuar. The largest signal is always used actuate the valve. The regulars mainly consist of the Type 2423 Valve with seat, plug and restriction gether with the Type 2427 or Type 2429 Closing Actuar with operating diaphragms. Valve and actuar are delivered separately and must be assembled on site using a coupling nut The medium flows through the valve in the direction indicated by the arrow. The position of the restriction (1.1) and the area released by the valve plug (3) determine the flow rate and the differential pressure p across the plant. The valve is fully balanced. The forces acting on the valve plug created by the upstream and downstream pressures are balanced by a balancing bellows (5) or balancing diaphragm (Type 2423 balanced by a diaphragm, DN ). The principle of operation of the regulars with valves balanced by a bellows or diaphragm only differ concerning the pressure balancing. The valves balanced by a diaphragm have a balancing diaphragm (Fig. 3) instead of a bellows (Fig. 2). The downstream pressure p 2 acts on the inside and the upstream pressure p 1 on the outside of the diaphragm. As a result, the forces acting on the valve plug are balanced out. Type 42-37: The high pressure of p is transmitted through the control line (18) the diaphragm chamber D. The high pressure of the flow rate (V. ) upstream of the restriction (1.1) is transmitted through the control line (19) the diaphragm chamber C. This pressure is equal the low pressure of p. The low pressure of V. downstream of the restriction is transmitted through holes in the plug and diaphragm stems the diaphragm chamber A. If, for example, the differential pressure rises, the positioning force at the botm operating diaphragm (13.2) rises, o. This change in force causes the diaphragm stems (12.2 and 12.1) and the valve plug (3) move in the closing direction until the set point adjusted at the set point spring (16) is reached. If the flow rate increases, the differential pressure at the restriction (1.1) and the resulting positioning force at the p diaphragm (13.1) increase. This change in differential pressure at the restriction causes the p diaphragm stem (12.1) push the plug stem and the valve plug (3) in the closing direction until the adjusted flow set point is reached. The largest signal is always used actuate the valve. The overload protection (force limiter with internal excess pressure limiter) (15) protects the seat, plug and plant during extreme operating conditions against overloading. Type 42-39: The principle of operation is almost the same as for Type However, the high pressure of the flow rate V. is separate from the low pressure of the differential pressure p in the Type 2429 Actuar. The diaphragm chambers for these pressures have their own control line connections. 4 EB 3017 EN

5 Design and principle of operation Type Type Type 2423 Valve balanced by a bellows A 9 A V 13.1 V B B C C D 21 D Type Actuar Type Actuar 1 Valve body 8 Venting (DN 125 and higher) 1.1 Restriction for flow set point 9 Differential pressure spring 1.2 Lock nut 11 Coupling nut 1.3 Cap 12.1 Top diaphragm stem 2 Seat 12.2 Botm diaphragm stem 3 Plug 13.1 Top operating diaphragm 4 Plug stem 13.2 Botm operating diaphragm 5 Balancing bellows 15 Overload protection (force 7 Spring limiter with internal excess pressure limiter) Fig. 2 Sectional drawings of regular with valve balanced by a bellows 16 Set point spring 17 Set point adjustment 18 Control line on site 19 Control line (+) V. 20 Control line (+) p 21 Restriction dampen signal EB 3017 EN 5

6 Design and principle of operation Type 42-37/Type DN Balanced by a diaphragm Type 2423 Valve balanced by a diaphragm Type 2427/2429 Actuar 1 Valve body 1.1 Restriction for flow set point 1.2 Lock nut 1.3 Cap 2 Seat 3 Plug 5 Balancing diaphragm 7 Plug stem 18 Control line Fig. 3 Sectional drawing of regular with valve balanced by a diaphragm Note on Type DoT and Type DoT These regulars can also be used for temperature control and limitation in combination with Type 2231 Temperature Regular by using a double adapter DoT. Refer the following Mounting and Operating Instructions in this case: EB 3019 EN for DoT double adapter and EB 2231 EN for Type Control Thermostats. 6 EB 3017 EN

7 Installation 2 Installation Install Type Regular in the low pressure line (return flow) of the plant. Install Type Regular in the high pressure line (flow) of the plant. Refer installation schematics in Fig. 4. On selecting the position of installation, make sure that the regular can still be easily accessed after completion of the plant. NOTICE The regular must be installed free of stress. If necessary, support the piping near the connections. However, do not attach supports the valve or actuar. Type in flow pipe Differential pressure and flow rate control Type in return flow pipe Differential pressure and flow rate control Type in flow pipe Pressure and flow rate control 1 Shut-off valve 2 Strainer 3 Flow and differential pressure regular 4 Equalizing tank, required for medium temperatures above 150 C or for steam applications 5 Needle valve 6 Pressure gauge 7 Bypass with capped valve (recommended) for set point adjustment Fig. 4 Installation schematics (p) and typical installation (botm) EB 3017 EN 7

8 Installation Note: Install a strainer (e.g. SAMSON Type 2 N/2 NI) upstream of the regular prevent sealing particles, welding spatter or other impurities carried along by the process medium from impairing the proper functioning of the valve, especially tight shut-off. 2.1 Mounting position See Fig. 5 for permissible mounting positions. Standard mounting position Install valve without actuar in a horizontal pipeline with the connection for the actuar facing downwards. Make sure the medium flows through the valve in the direction indicated by the arrow. Then connect the actuar the valve using the coupling nut (11). NOTICE Protect the regular when it is used control freezing process media. On shutting down the plant in areas not free from frost, depressurize and empty the regular and remove it from the pipeline. 2.2 Control line, equalizing tank and needle valve Control lines Control lines preferably using 8 x 1 mm steel or stainless steel pipe must be provided at the site of installation. Connect the control line for pressure tapping in Type the pipeline upstream of the consumer. Make sure the pressure tapping point is at least 3 x DN away from any instruments (pipe manifolds, distriburs, other valves) that can cause turbulence in the flow Standard mounting position all versions Above 80 C, steam applications All versions in DN and up max. 80 C Only versions with fixed plug guide and up max. 80 C Fig. 5 Permissible mounting positions (Fig. 6.1). How the line is routed generally depends on the installation location. The same rules apply the control line installed on site for Type (connected downstream of the consumer). We recommend connecting the control line at the side of the main pipeline (Fig. 5.4). Do not change the pipe diameter of the main pipeline so that it is off center! Type Attach the supplied low-pressure control line the regular as shown in Fig. 2. At the site of installation, route the high-pressure control line with 8 mm (standard), 10 mm or 12 mm pipe diameter from the botm diaphragm chamber the high-pressure line (flow) of the plant. 8 EB 3017 EN

9 Installation Type Attach the supplied control lines the regular as shown in Fig. 2. When used as a flow and differential pressure regular, additionally route a control line at the site of installation from diaphragm chamber C the low-pressure line (return flow) of the plant. When used as a flow and pressure regular, leave the connection for diaphragm chamber C open. Control line kit A control line kit for tapping pressure directly at the valve body is available as an accessory from SAMSON. Refer Data Sheet T 3095 EN. Needle valve If the regular tends hunt, we recommend installing a SAMSON needle valve in the control line routed on site at the actuar connection. Correct! 6.4 Connection at the side correct Incorrect! 6.3 Connection at the p incorrect Incorrect! Note: Needle valves, equalizing tanks and compression-type screw fittings can be supplied as required. These accessories are listed in the Data Sheet T 3095 EN. Equalizing tank An equalizing tank is required for liquids above 150 C. Prior start-up, fill the equalizing tank with the medium be regulated. This prevents hot medium coming in direct contact with the diaphragm. Depending on how the regular is installed, install the equalizing tank in any control line used with hot media. The mounting position of the equalizing tank is indicated by an adhesive label on the tank itself as well as by an arrow and the word "p" stamped on the p of the tank. 6.2 Connection at the botm incorrect min. 3 x DN min. 3 x DN M DN min. 3 x DN DN = Nominal size 6.1 Control line connection, depending on how the pipeline is routed Fig. 6 Connection of control lines EB 3017 EN 9

10 Installation Install the equalizing tank near the pressure tapping point in the flow pipe or at the same height as the valve (Fig. 7) ensure that the control line reaches from at least the mid axis the valve the actuar. This ensures that a hot medium can cool down sufficiently. NOTICE Adhere the mounting position and distances prescribed, otherwise the safe functioning of the regular cannot be guaranteed. 2.3 Strainer A strainer installed in the flow pipe prevents foreign matter and dirt particles in the medium from entering the regular. The SAMSON product range includes the Type 2 N/2 NI Strainer (refer Data Sheet T 1015 EN). Install the strainer upstream of the regular. Make sure the direction of medium flow corresponds 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. Remember leave enough space remove it. T 1 >150 C 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 be able shut down the plant for cleaning and maintenance, and when the plant is not used for longer periods of time. Minimum length of control line Type T 2 <150 C 2.5 Pressure gauge To monir the pressures in the plant, install a pressure gauge both upstream and downstream of the regular. Install the pressure gauge on the downstream side behind the downstream pressure tapping point. Fig. 7 Type with equalizing tank 10 EB 3017 EN

11 Operation 3 Operation 3.1 Start-up CAUTION! First start up the regular after mounting all the components, e.g. valve, actuar and control lines. Make sure the control lines are open and correctly connected before start-up. Note: On filling the plant, make sure the restriction (1.1) is open by turning the adjustment screw counterclockwise as far as it will go. Open 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 (8) at the spper located at the side of the bellows housing. If needle valves are installed in the control lines, open them before start-up. Fill equalizing tanks with the process medium before start-up. Rinsing the plant After filling the plant, first completely open the consumers. If this is not possible open the bypass. Open the restriction for flow rate adjustment with a differential pressure set point spring at maximum compression. 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 necessary. NOTICE The pressure at the actuar must not exceed the nominal pressure by 1.5 times on testing the pressure of the plant when the regular is already installed The control lines must route the test pressure the actuar at the same time prevent the actuar diaphragms from being damaged. When Type is used as a flow and pressure regular, do not connect the control line diaphragm chamber C. 3.2 Set point adjustment Set point for flow rate Note: Before adjusting the flow rate, you first need adjust the set point for the differential pressure (or pressure) its maximum value, To do this, turn the nut (17) clockwise load the set point spring (16). The control valves and shut-off valves as well as all consumers or a bypass valve, if applicable, must be opened reach the maximum flow rate, but without the high differential pressure (pressure) being able close the valve. Turn the restriction (1.1) until the required flow rate is reached, by reading, for example, the flow rate reading off a heat meter (see Table 1 Flow rate set point ranges). Note: Always start the adjustment from a closed restriction! EB 3017 EN 11

12 Operation Turn clockwise close the restriction. This reduces the flow rate. Turn counterclockwise open the restriction. This raises the flow rate. You can also use the adjustment diagrams for water in Figs. 8, 9 and 10 on the following pages help you make the flow rate adjustment. Note: The differential pressure at the restriction p restriction is fixed at either 0.2 bar or 0.5 bar (see nameplate) by the differential pressure spring(s) (9) in the actuar. Unscrew cap (1.3) and undo lock nut (1.2). Turn the adjustment screw clockwise as far as it will go. Find the flow set point in the diagram and determine how many turns are required. Turn the screw counterclockwise (based on a closed restriction) until the selected set point is adjusted. Check the flow rate at the heat meter and correct, if necessary. When 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. Close the open bypass valve again, if applicable. Table 1 Flow rate set point ranges for water Type 2423 Balanced by a bellows Nominal size DN Flow rate set point ranges for water in m³/h Differential pressure at restriction p restriction = 0.2 bar Differential pressure at restriction p restriction = 0.5 bar Type 2423 Balanced by a diaphragm Nominal size DN Flow rate set point ranges for water in m³/h Differential pressure at restriction p restriction = 0.2 bar EB 3017 EN

13 Operation p restriction = 0.5 bar Turns of set point adjustment (orifice) prestriction = 0.2 bar Adjustment diagrams valid for water Turns of set point adjustment (orifice) Fig. 8 Adjustment diagram for Type 2423 balanced by a bellows, DN EB 3017 EN 13

14 Operation p restriction = 0.5 bar Turns of set point adjustment (orifice) prestriction = 0.2 bar Adjustment diagrams valid for water Turns of set point adjustment (orifice) Fig. 9 Adjustment diagram for Type 2423 balanced by a bellows, DN EB 3017 EN

15 Operation Adjustment diagrams valid for water Turns of set point adjustment (orifice) DN 125, DN 150 A = 320 cm 2 p restriction = 0.2 bar Balanced by a diaphragm DN 200, DN 250 A = 320 cm 2 p restriction = 0.2 bar Balanced by a diaphragm Fig. 10 Adjustment diagram for Type 2423 balanced by a diaphragm, DN 125 DN Set point for differential pressure Note: Before adjusting the differential pressure, reduce the maximum flow rate by approximately 5 % by closing a shut-off valve on the consumer side or the bypass. If a morized valve is used in the plant, close this by approximately 10 % of its travel. Turn the nut (17) counterclockwise unload the set point springs (16) and adjust the differential pressure set point. While doing this, compare the pressures upstream and downstream of the consumer by reading off the installed pressure gauges (see Fig. 4). If you want adjust small differential pressure set points, we recommend using a differential pressure gauge instead of two pressure gauges. Turn the nut (17) clockwise increase the set point. Turn the nut (17) counterclockwise reduce the set point. EB 3017 EN 15

16 Operation Pressure set point in Type Flow and Pressure Regular Adjust the pressure set point at the nut (17). While doing this, read the pressure off the installed pressure gauge on the downstream side. Turn the nut (17) clockwise increase the downstream pressure. Turn the nut (17) counterclockwise reduce the downstream pressure. 3.3 Decommissioning Close the shut-off valves starting from the upstream side (high-pressure line). CAUTION! On performing any work on the regular, make sure the relevant section of the pipeline is depressurized and, depending on the process medium, drained as well. For high temperatures, allow the regular cool down ambient temperature before starting any work on it. Interrupt or shut off the control line avoid any hazards which could be caused by moving parts. As valves are not free of cavities, remember that residual process medium might still be contained in the valve. We recommend remove the valve from the pipeline. Make sure that all the plant sections connected the control lines are also depressurized. If this is not the case, shut off the control lines. 16 EB 3017 EN

17 Cusmer service 4 Cusmer service Should any malfunctions or any defect occur, SAMSON's After-Sales Service is prepared help you on site. You can also send the defective regular directly your local SAMSON representative for repair. Addresses of SAMSON subsidiaries, agencies and service centers are listed in the product catalogs and in the Internet at To allow SAMSON find the fault and have an idea of the installation situation, specify the following details (refer the nameplate): Type and nominal size of the valve Threaded or flanged end connections Model number Upstream and downstream pressure Flow rate in m 3 /h Has a strainer been installed? Sketch of the installation with exact position of regular and all additional installed components (shut-off valves, pressure gauges, etc.). EB 3017 EN 17

18 Maintenance Troubleshooting 5 Maintenance Troubleshooting The regulars are maintenance free. Nevertheless, they are subject natural wear, particularly at the seat, plug and operating diaphragm. Depending on the operating conditions, the regular needs be checked at regular intervals avoid possible malfunctions. Details on faults and the recommended action can be found in the table below. Table 2 Troubleshooting Malfunction Possible reasons Recommended action Flow rate or differential pressure exceeds its set point Flow rate or differential pressure set point is not reached Control loop hunts Seat and plug untight Operating diaphragm defective Control line blocked Valve o large for flow control or o small for differential pressure control Seat and plug untight Wrong set point range selected Safety equipment, e.g. pressure limiter, has been triggered Insufficient pressure drop across the plant Strainer blocked Direction of flow, valve incorrectly installed Valve o large for the control task at hand Restriction (or needle valve) is missing in a control line dampen pulsation Remove valve from pipeline. Clean seat and plug. Replace plug, if necessary. Otherwise send the regular SAMSON for repair. Replace diaphragm or send the regular SAMSON for repair. Remove control line and clean it. Recalculate K VS coefficient and contact SAMSON for further action. Remove valve from pipeline. Clean seat and plug. Replace plug, if necessary. Otherwise send the regular SAMSON for repair. Check set point range and contact SAMSON for further action. Check plant and unlock safety equipment. Compare existing differential pressure in the plant with the plant s drag. Differential pressure across the plant p min =. p restriction + (V/ KVS)². Drain and clean filter of the strainer Install the valve so that the direction of flow is the same as indicated by the arrow. Recalculate K VS coefficient. Contact SAMSON. Check restriction in the connection chamber D (Type 42-37) or chamber C (Type 42-39). If necessary, install a needle valve in the control line and start 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 table. 18 EB 3017 EN

19 Nameplates 6 Nameplates Valve and actuar both have a nameplate. DIN version ANSI version Valve 1 Valve type 2 Model number 3 Model number index 4 Order number or order date 5 K VS coefficient 8 Nominal size 9 Nominal pressure 10 Perm. differential pressure in bar 11 Perm. temperature in C 12 Body material Valve nameplates ANSI version 5 Nominal size 8 Perm. differential pressure in psi 9 Perm. temperature in F 10 Body material 11 CV coefficient (K VS x 1.17) 12 ANSI Class (pressure rating) Actuar nameplate Actuar 1 Model number 2 Model number index 3 Order number or order date 4 Effective diaphragm area 5 Labeling acc. DIN 6 Labeling acc. ANSI 7 Max. perm. pressure 8 Nominal size 9 Differential pressure at restriction 10 Set point range 11 Diaphragm material 12 Year of production Fig. 11 Nameplates EB 3017 EN 19

20 Technical data 7 Technical data Table 3 Technical data Type Type Type 2423 Valve Balanced by a bellows Nominal size DN 15 DN 100 DN 125 DN 250 Nominal pressure PN 16, 25 or 40 (acc. DIN EN ) Pressure at which internal 160 cm² 1.2 bar excess pressure limiter responds (Type only) 320 cm² 0.6 bar Max. perm. temperature Differential pressure or pressure set point Leakage rate Type 2423 Valve Balanced by a diaphragm Valve body See pressure-temperature diagram Actuar 1) With equalizing tank: Liquids up 220 C Without equalizing tank: Liquids up 150 C bar ) 0.05 % of K VS coefficient Nominal size DN 125 DN 250 Nominal pressure PN 16, 25 or 40 (acc. DIN EN ) Pressure at which internal excess pressure limiter responds (Type only) Max. perm. temperature Differential pressure or pressure set point Leakage rate 1) Higher temperatures possible on request 2) On request 160 cm² 1.2 bar 320 cm² 0.6 bar 640 cm² 0.3 bar Valve body See pressure-temperature diagram Actuar 1) Liquids up 150 C bar bar bar bar 2 5 bar 2) 0.05 % of K VS coefficient 20 EB 3017 EN

21 Dimensions 8 Dimensions Dimensional drawing Type 2423 Valve balanced by a diaphragm Type 42-37/Type Fig. 12 Dimensions of Type 2423 Valve balanced by a diaphragm Table 4 Dimensions in mm and weights in kg Type 2423 Valve balanced by a diaphragm Type 2423 Valve balanced by a diaphragm Nominal size DN 125 DN 150 DN 200 DN 250 Length L Height H Height H Weight for PN 16 1) in kg Type 2423 Valve Type 2427/2429 Actuar ) PN 25/40: +10 % EB 3017 EN 21

22 Dimensions Dimensional drawing Type 2423 Valve balanced by a bellows Type 42-37/Type Fig. 13 Dimensions of Type 2423 Valve balanced by a bellows 22 EB 3017 EN

23 Dimensions Table 5 Dimensions in mm and weights in kg Type 2423 Valve balanced by a bellows Type 2423 Valve balanced by a bellows Nominal size DN Length L Height H Height H2 Other materials bar Height H 1) Ø D = 285 mm, Actuar Ø D = 225 mm, A = 160 cm² A = 320 cm² Weight 2) Height H 1) Set point range bar bar Actuar Ø D = 225 mm, A = 160 cm² 4) Ø D = 285 mm, A = 320 cm² Weight 2) Height H 1) Actuar Ø D = 225 mm, A = 160 cm² 4) Ø D = 285 mm, A = 320 cm² Weight 2) bar Height H 1) Actuar Ø D = 225 mm, A = 160 cm² Ø D = 285 mm, A = 320 cm² Weight 2) Height H 1) Actuar Ø D = 225 mm, A = 160 cm² 5 bar Weight 2) ) Add 50 mm height H for Type ) The weight applies the version with material specifications EN-JL 1040/PN 16. Add 10 % this weight for versions made of cast steel /PN 40, spheroidal graphite iron EN-JS 1049/ PN 25 and / ) p = 4.5 bar 10 bar on request 4) Optionally also with actuar 320 cm² (DN ).We recommend actuar 320 cm² for regulars with double adapter (see T 3019 EN) in sizes DN 65 DN 100. EB 3017 EN 23

24 SAMSON AG MESS- UND REGELTECHNIK Weismüllerstraße Frankfurt am Main Germany Phone: Fax: Internet: EB 3017 EN S/Z