Samson 44-6 B Service-Handbuch

Self-operated Pressure Regulators

Type 44-6 B · Excess Pressure Valve

Mounting and

Operating Instructions

EB 2626-2 EN

Edition November 2010

Type 44-6 B Excess Pressure Valve,

stainless steel body

Type 44-6 B Excess Pressure Valve,

red brass body

2EB 2626-2 EN

Contents

Contents Page

1 Design and principle of operation . . . . . . . . . . . . . . . . . . . . . . 4

1.1 Process medium, application range . . . . . . . . . . . . . . . . . . . . . 4

2 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

2.1 Mounting position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

2.2 Strainer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

2.3 Shut-off valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

2.4 Pressure gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

3 Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

3.1 Start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

3.2 Adjusting the set point . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

3.3 Decommissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

4 Maintenance and troubleshooting . . . . . . . . . . . . . . . . . . . . . . 8

4.1 Cleaning and replacing the plug . . . . . . . . . . . . . . . . . . . . . . . 8

4.2 Replacing the operating bellows . . . . . . . . . . . . . . . . . . . . . . . 9

4.3 Replacing the set point spring . . . . . . . . . . . . . . . . . . . . . . . . 9

5 Nameplate. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

6 Service. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

7 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

8 Dimensions and weights . . . . . . . . . . . . . . . . . . . . . . . . . . 13

CAUTION!

Indicates a hazardous situation which, if not

avoided, could result in minor or moderate in-

jury.

NOTICE

Indicates a risk of property damage.

Note! Indicates supplementary explanations,

information and tips.

Definitions of the signal words used in these instructions

EB 2626-2 EN 3

Safety instructions

General safety instructions

Observe the following instructions on installation, start-up and operation of the regulator for

your own safety:

4The regulator is to be mounted, started up or serviced by fully trained and qual-

ified 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 mounting and operating instruc-

tions, particularly those concerning assembly, start-up and maintenance, must

be observed.

4According to these mounting and operating instructions, trained personnel re-

fers to individuals who are able to judge the work they are assigned to and rec-

ognize possible dangers due to their specialized training, their knowledge and

experience as well as their knowledge of the applicable standards.

4The regulator fulfils the requirements of the European Pressure Equipment Di-

rective 97/23/EC.

4For appropriate operation, make sure that the regulator is only used in areas

where the operating pressure and temperatures do not exceed the sizing data

specified in the order.

4The manufacturer does not assume any responsibility for damage caused by

external forces or any other external influence!

4Any hazards that could be caused in the regulator by the process medium, the

operating pressure or by moving parts are to be prevented by means of the ap-

propriate measures.

4Proper transport, storage, installation, operation and maintenance are as-

sumed.

Note! Non-electric valve versions whose bodies 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, section 5.2, even in the rare inci-

dent of an operating fault. Therefore, such valve versions do not fall within the

scope of Directive 94/9/EC.

For connection to the equipotential bonding system, observe section 6.3 of

EN 60079-14:2008, VDE 0165-1.

1 Design and principle of oper-

ation

Also see Fig. 1 on page 5.

The excess pressure valve consists of the

valve (1) including the seat (3), plug (2) and

balancing bellows (6) as well as an actuator

section with operating bellows (5), set point

spring (7) and set point adjuster (8/9).

The excess pressure valve is designed to

maintain the pressure upstream of the valve

constant at the adjusted set point.

In pressureless state, the valve is closed. It is

opened when the upstream pressure exceeds

the adjusted set point. The process medium

flows through the valve in the direction indi-

cated by the arrow on the body. The position

of the valve's plug (2) determines the flow rate

across the area released between the plug

and seat (3), and thus the pressure upstream

of the valve.

The upstream pressure p1to be controlled is

transmitted through a bore (4) in the valve

body to the operating bellows (5) where it is

converted into a positioning force. This force is

used to move the plug depending on the force

of the set point spring (7). The spring force can

be adjusted on the set point adjuster (8/9).

1.1 Process medium, application

range

Type 44-6 B Excess Pressure Valve for gases,

liquids and steam

Max. permissible temperatures:

–Non-flammable gases up to 80 °C

–Liquids up to 150 °C

–Nitrogen up to 200 °C

–Steam up to 200 °C

2 Installation

Thoroughly flush the pipeline before installing

the regulator to remove any sealing parts,

weld spatter and other impurities carried

along by the process medium that may impair

the proper functioning of the valve, above all

its tight shut-off.

Make sure the regulator is mounted free of

stress. If necessary, support the piping near

the connecting flanges. Never attach supports

directly to the valve or actuator.

NOTICE

Install a strainer (e.g. SAMSON Type 2 NI

with 0.25 mm mesh size) upstream of the reg-

ulator (refer to section 2.2).

2.1 Mounting position

Install the regulator with the direction of flow

matching the arrow on the body.

– Installation in any desired po-

sition for liquids and gases

≤150 °C

–Installation in horizontal pipe-

lines with the actuator body

pointing down for steam

≥150 °C (see photo)

NOTICE

Make sure no overheating occurs at the place

of installation due to excessive ambient tem-

peratures or insufficient heat dissipation.

As a result, never insulate red brass bodies

together with the medium pipeline.

4EB 2626-2 EN

Design and principle of operation

EB 2626-2 EN 5

Installation

1 Valve body

1.1 Body gasket

2 Plug

3 Seat

4 Bore for control pressure

5 Operating bellows

6 Balancing bellows (not for 0.2

to 2 bar set point range with

standard plug)

7 Set point spring

8 Set point adjuster

9 Set point screw

10 Screws

11 Screw plug

11.1 Sealing ring

Type 44-6 B · Version with threaded body made of

red brass

Set point screw

Stainless steel or spheroidal graphite iron version

(DN 40 and 50) and 8 to 20 bar set point range ·

SW 3 or 5 hexagon socket screw (spheroidal

graphite iron)

2p1p2

(40 Nm)

11.1

1.1

(10 Nm)

Fig. 1 · Design and principle of operation, Type 44-6 B

Valve

Actuator housing

2.2 Strainer

Install a strainer upstream of the regulator

(Fig. 2). Install the strainer with the direction

of flow matching the arrow on the body.

In horizontal pipelines, install the strainer with

the filter element pointing down. For steam,

install the strainer with the filter element point-

ing to the side.

In vertical pipelines with the direction of flow

from bottom to top, the drain flange of the fil-

ter element points up. In this case, dirt parti-

cles are not collected, but retained.

Remember to leave enough space to remove

the filter element.

2.3 Shut-off valve

Install a hand-operated shut-off valve both

upstream of the strainer and downstream of

the regulator (Fig. 2) to be able to shut down

the plant for cleaning and maintenance, and

when the plant is not used for longer periods

of time.

2.4 Pressure gauge

To monitor the pressures in the plant, install a

pressure gauge both upstream and down-

stream of the regulator (Fig. 2).

6EB 2626-2 EN

Installation

12 4

351

Fig. 2 · Sample installation scheme

1 Shut-off valve

2 Upstream pressure gauge

3 Strainer

4 Type 44-6 B Excess Pressure Valve

5 Downstream pressure gauge

p1p2

3 Operation

3.1 Start-up

CAUTION!

Do not start up the regulator before all com-

ponents have been installed.

We recommend to open shut-off valves

slowly from the upstream side. Avoid pres-

sure surges.

NOTICE

When pressure-testing the pipelines with the

regulator installed, make sure the regulator is

not damaged by the test pressure.

Make sure the maximum permissible pres-

sure of 1.5 times the nominal pressure PN is

not exceeded.

Protect the regulator against frost when it is

used to control freezing process media (e.g.

water). When the regulator is not used for

longer periods of time, remove it from the

pipeline, if necessary.

3.2 Adjusting the set point

Also see Fig. 1 on page 5.

Adjust the desired set point by turning the set

point adjuster (8) or set point screw (9).

Turn the set point adjuster or screw:

4Clockwise P

to increase the pressure set point

4Counterclockwise Q

to reduce the pressure set point

Version with stainless steel or spheroidal

graphite iron body (DN 40 and 50) and 8 to

20 bar set point range:

1. Loosen the lock nut.

2. Adjust the set point by turning the set

point screw (9) clockwise or counter-

clockwise using an SW 3 or 5 Allen key

(spheroidal graphite iron body).

3. Retighten the lock nut.

Check the adjusted set point on the pressure

gauge installed upstream of the regulator

(Fig. 2).

The set point range can be changed by re-

placing the set point spring (7; refer to sec-

tion 4.3).

3.3 Decommissioning

We recommend to close the upstream shut-off

valve before closing the shut-off valve down-

stream of the regulator.

EB 2626-2 EN 7

Operation

4 Maintenance and trouble-

shooting

The pressure regulator is maintenance free.

Nevertheless, it is subject to natural wear,

particularly at the seat, plug and operating or

balancing bellows.

Depending on the operating conditions,

check the regulator at regular intervals to de-

tect and remove possible malfunctions.

If external leaks occur, check the operating

bellows (refer to section 4.2), and replace it, if

necessary.

Refer to Table 1 to determine the cause of ex-

isting faults and remove them. This may help

to re-establish the regulator's proper func-

tioning.

Note! Refer to Spare Parts List EL 2626 for

original spare parts to be ordered from

SAMSON (refer to section 6).

CAUTION!

For installation and maintenance work on the

regulator, depressurize the relevant plant sec-

tion and, depending on the process medium,

drain it as well. We recommend to remove the

regulator from the pipeline.

If necessary, allow the regulator to cool down

to reach ambient temperature before starting

any work on it.

As valves are not free of cavities, remember

that residual process medium might still be

contained in the valve.

4.1 Cleaning and replacing the

plug

Also see Fig. 1 on page 5.

Use a socket wrench (order no. 1280-3001)

to remove the screw plug (11). This wrench

can also be made, for example from a screw-

driver bit (IN 19-19) by boring a

17-mm-deep hole (Ø 17) into the 19 mm

hexagon bit as shown in Fig. 3.

1. Relieve the set point spring (7) by turn-

ing the set point adjuster (8/9) counter-

clockwise Q.

2. Unscrew the screw plug (11). Pull out the

balancing bellows (6) together with the

plug (2) and plug stem.

3. Thoroughly clean the seat and plug.

If the plug or balancing bellows are

damaged, replace the entire assembly

(remember that there is no balancing

bellows with the standard plug for 0.2 to

2 bar set point range).

4. Replace the sealing ring (11.1) with a

new one.

5. For assembly, proceed in reverse order.

Observe the tightening torques given in

Fig. 1.

8EB 2626-2 EN

Maintenance and troubleshooting

Ø 17

SW 19

Fig. 3 · Socket wrench as special tool

4.2 Replacing the operating bel-

lows

Also see Fig. 1 on page 5.

1. Relieve the set point spring (7) by turn-

ing the set point adjuster (8/9) counter-

clockwise Q.

CAUTION!

Be careful when loosening the screws as the

set point spring is still slightly pretensioned.

2. Unscrew the screws (10) evenly.

3. Remove the lower actuator section includ-

ing set point spring (7) and operating bel-

lows (5).

4. Remove the operating bellows and re-

place it with a new one.

5. Replace the body gasket (1.1) with a

new one.

6. For assembly, proceed in reverse order.

Observe the tightening torques given in

Fig. 1.

4.3 Replacing the set point

spring

Also see Fig. 1 on page 5.

The set point spring is located in the actuator

housing. Remove the actuator housing from

the valve to replace the spring.

1. Fully relieve the set point spring (7) by

turning the set point adjuster (8/9) coun-

terclockwise Qall the way.

CAUTION!

Be careful when loosening the screws as the

set point spring is still slightly pretensioned.

2. Unscrew the screws (10) evenly.

3. Remove the lower actuator section in-

cluding set point spring (7) and operat-

ing bellows (5).

4. Remove the set point spring and replace

it with a new one.

5. Replace the body gasket (1.1) with a

new one, if necessary.

6. For assembly, proceed in reverse order.

Observe the tightening torques given in

Fig. 1.

EB 2626-2 EN 9

Maintenance and troubleshooting

Table 1 · Troubleshooting and fault removal

Fault Possible cause Remedy

Pressure exceeds

the adjusted set

point

Insufficient pressure pulse on the oper-

ating bellows Connect control line in special version

without control line. Clean control line

and screw joint.

Pressure tapped in wrong location in

special version with external control

line

Reroute control line. Do not connect it

to pipe elbows or necks.

Wear on seat and plug due to deposits

or foreign particles Replace damaged parts.

Plug blocked by foreign particles Remove foreign particles. Replace

damaged parts as necessary.

Valve installed against the direction of

flow Check that valve is installed with the

direction of flow matching the arrow

on the valve body.

Pressure drops be-

low the adjusted set

point

Plug blocked by foreign particles Remove foreign particles. Replace

damaged parts as necessary.

Jerky control

response Increased friction, e.g. due to foreign

particles in seat-plug trim Remove foreign particles. Replace

damaged parts as necessary.

Slow control

response Dirt inside control line impedes me-

dium flow Clean control line.

Upstream pressure

fluctuates Valve too large Check valve sizing. Change KVS/CV

coefficient or install suitable regulator.

Pressure tapped in wrong location in

special version with external control line Reroute control line. Do not connect it

to pipe elbows or necks.

Severe noise

emissions High flow velocity, cavitation Check valve sizing. If necessary, install

a larger regulator.

Special operating and installation conditions can lead to changed situations that may affect the

control response and lead to malfunctions. In such cases, check the installation conditions, pro-

cess medium, temperature and pressure conditions. A thorough analysis may require the

on-site assistance of the SAMSON After-sales Service staff (refer to section 6).

10 EB 2626-2 EN

Maintenance and troubleshooting

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