Samson 44-7 Service-Handbuch

Translation of original instructions

EB 2723 EN

Type44-7 Excess Pressure Valve

Type44-4 and Type44-8 Safety Excess Pressure Valves (SEV)

Self-operated Pressure Regulators

Edition March 2019

Type44-7 Excess Pressure Valve

Red brass body with screwed ends

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 2723 EN

Contents

EB 2723 EN 3

1 Safety instructions and measures ...................................................................5

1.1 Notes on possible severe personal injury .........................................................7

1.2 Notes on possible personal injury ...................................................................8

1.3 Notes on possible property damage ................................................................9

2 Markings on the device ...............................................................................10

2.1 Regulator nameplate ....................................................................................10

2.2 Material number ..........................................................................................11

2.3 Warnings ....................................................................................................11

3 Design and principle of operation ................................................................12

3.1 Technical data .............................................................................................14

4 Measures for preparation............................................................................18

4.1 Unpacking ..................................................................................................18

4.2 Transporting and lifting ................................................................................18

4.3 Storage .......................................................................................................18

4.4 Preparation for installation ............................................................................19

5 Mounting and start-up.................................................................................20

5.1 Mounting positions .......................................................................................20

5.2 Additional ttings .........................................................................................21

5.3 Start-up .......................................................................................................22

5.4 Gases and liquids ........................................................................................22

6 Operation...................................................................................................22

6.1 Adjusting the set point ..................................................................................22

7 Servicing.....................................................................................................23

7.1 Cleaning and replacing the seat and plug ......................................................24

7.2 Exchanging the operating diaphragm ............................................................26

7.3 Replacing the set point springs ......................................................................28

7.4 Tightening torques and lubricant ...................................................................29

7.5 Preparation for return shipment .....................................................................30

7.6 Ordering spare parts and operating supplies .................................................30

8 Malfunctions ...............................................................................................30

Contents

4 EB 2723 EN

9 Decommissioning and removal ....................................................................33

9.1 Decommissioning .........................................................................................33

9.2 Disposal ......................................................................................................33

10 Appendix....................................................................................................34

10.1 After-sales service ........................................................................................34

10.2 Spare parts .................................................................................................34

10.3 Certicates ..................................................................................................37

EB 2723 EN 5

Safety instructions and measures

1 Safety instructions and measures

Intended use

The SAMSON Type44-4, Type44-7 and Type44-8 Pressure Regulators are suitable for

pressure control of liquids and gases. The regulators are designed to operate under exactly

dened conditions (e.g. operating pressure, process medium, temperature). Therefore,

operators must ensure that the regulators are only used in operating conditions that meet the

specications used for sizing the devices at the ordering stage. In case operators intend to

use the regulators in other applications or conditions than specied, contact SAMSON.

SAMSON does not assume any liability for damage resulting from the failure to use the de-

vice for its intended purpose or for damage caused by external forces or any other external

factors.

ÎRefer to the technical data and nameplate for limits and elds of application as well as

possible uses.

Reasonably foreseeable misuse

The regulators are not suitable for the following applications:

−Use outside the limits dened during sizing and by the technical data

−Use outside the limits dened by the accessories mounted on the regulator

Furthermore, the following activities do not comply with the intended use:

−Use of non-original spare parts

−Performing service and repair work not described in these instructions

−Changing parts, service or repair work on TÜV-tested Type44-4 and Type44-8

Qualications of operating personnel

The regulator must be mounted, started up, serviced and repaired by fully trained and

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

hazards due to their specialized training, their knowledge and experience as well as their

knowledge of the applicable standards.

6 EB 2723 EN

Safety instructions and measures

Personal protective equipment

We recommend checking the hazards posed by the process medium being used (e.g.

uGESTIS (CLP) hazardous substance database).

ÎProvide protective equipment (e.g. safety gloves, eye protection) appropriate for the pro-

cess medium used.

ÎWear hearing protection when working near the regulator.

ÎCheck with the plant operator for details on further protective equipment.

Revisions and other modications

Revisions, conversions or other modications of the product are not authorized by SAMSON.

They are performed at the user's own risk and may lead to safety hazards, for example.

Furthermore, the product may no longer meet the requirements for its intended use.

Warning against residual hazards

To avoid personal injury or property damage, plant operators and operating personnel must

prevent hazards that could be caused in the regulator by the process medium, the operating

pressure, the signal pressure or by moving parts by taking appropriate precautions. They

must observe all hazard statements, warning and caution notes in these mounting and oper-

ating instructions, especially for installation, start-up and service work.

We also recommend checking the hazards posed by the process medium being used (e.g.

uGESTIS (CLP) hazardous substance database).

ÎObserve safety measures for handling the device as well as re prevention and explosion

protection measures.

Responsibilities of the operator

The operator is responsible for proper operation and compliance with the safety regulations.

Operators are obliged to provide these mounting and operating instructions as well as the

referenced documents to the operating personnel and to instruct them in proper operation.

Furthermore, the operator must ensure that operating personnel or third persons are not ex-

posed to any danger.

Responsibilities of operating personnel

Operating personnel must read and understand these mounting and operating instructions as

well as the referenced documents and observe the specied hazard statements, warnings

and caution notes. Furthermore, the operating personnel must be familiar with the applicable

health, safety and accident prevention regulations and comply with them.

EB 2723 EN 7

Safety instructions and measures

Referenced standards and regulations

The regulators comply with the requirements of the European Pressure Equipment Directive

2014/68/EU. Regulators with a CE marking have an EU declaration of conformity, which

includes information about the applied conformity assessment procedure. This EU declaration

of conformity is included in the Appendix of these instructions (see section10.3).

According to the ignition risk assessment performed in accordance with EN13463-1:2009,

section 5.2, the non-electrical regulators do not have their own potential ignition source even

in the rare incident of an operating fault. As a result, they do not fall within the scope of Di-

rective 2014/34/EU.

ÎFor connection to the equipotential bonding system, observe the requirements specied in

section 6.4 of EN60079-14 (VDE0165 Part 1).

1.1 Notes on possible severe personal injury

DANGER

Risk of bursting in pressure equipment.

Regulators and pipelines are pressure equipment. Improper opening can lead to regu-

lator components bursting.

ÎObserve the maximum permissible pressure for regulator and plant.

ÎIf necessary, a suitable overpressure protection must be installed on site in the plant

section.

ÎBefore starting any work on the regulator, depressurize all plant sections

concerned.

ÎDrain the process medium from all the plant sections concerned as well as the reg-

ulator.

ÎWear personal protective equipment.

8 EB 2723 EN

Safety instructions and measures

1.2 Notes on possible personal injury

WARNING

Risk of personal injury due to preloaded springs.

Regulators in combination with preloaded set point springs are under tension. These

regulators can be identied by the red warning label on the actuator's set point springs.

ÎBefore starting any work on the set point springs, relieve the compression from the

preloaded springs.

ÎOnly use the SAMSON disassembly tool (1280-4052).

Crush hazard arising from moving parts.

The regulator contains moving parts (actuator and plug stems), which can injure hands

or ngers if inserted into the valve.

ÎDo not insert hands or ngers between the set point springs while the regulator is in

operation.

ÎBefore performing any work on the regulator, depressurize the plant. Disconnect or

shut off the external control line.

Risk of personal injury due to residual process medium in the regulator.

While working on the regulator, residual process medium can escape and, depending

on its properties, may lead to personal injury, e.g. (chemical) burns.

ÎIf possible, drain the process medium from all the plant sections concerned and the

regulator.

ÎWear protective clothing, safety gloves and eyewear.

Risk of burn injuries due to hot or cold components and pipelines.

Depending on the process medium, regulator components and pipelines may get very

hot or cold and cause burn injuries.

ÎAllow components and pipelines to cool down or heat up.

ÎWear protective clothing and safety gloves.

Damage to health relating to the REACH regulation.

If a SAMSON device contains a substance which is listed as being a substance of very

high concern on the candidate list of the REACH regulation, this circumstance is indicat-

ed on the SAMSON delivery note.

ÎInformation on safe use of the part affected uwww.samson.de/reach-en.html

EB 2723 EN 9

Safety instructions and measures

1.3 Notes on possible property damage

NOTICE

Risk of regulator damage due to contamination (e.g. solid particles) in the pipeline.

The plant operator is responsible for cleaning the pipelines in the plant.

ÎFlush the pipelines before start-up.

Risk of regulator damage due to unsuitable medium properties.

The regulator is designed for a process medium with dened properties.

ÎOnly use the process medium specied for sizing.

Risk of regulator damage due to the use of unsuitable lubricants.

The lubricants to be used depend on the regulator material. Unsuitable lubricants may

corrode and damage the surface.

ÎOnly use lubricants approved by SAMSON.

Risk of leakage and regulator damage due to excessively high or low tightening

torques.

Observe the specied torques on tightening regulator components. Excessively tightened

torques lead to parts wearing out quicker. Parts that are too loose may cause leakage.

ÎObserve the specied tightening torques.

Risk of regulator damage due to the use of unsuitable tools.

Certain tools are required to work on the regulator.

ÎOnly use tools approved by SAMSON.

SAMSON's After-sales Service department can support you concerning lubricant, tight-

ening torques and tools approved by SAMSON.

Note

10 EB 2723 EN

Markings on the device

2 Markings on the device

2.1 Regulator nameplate

1Model number

2 Conguration ID (Var.-ID) and device index

3 Order number or year of manufacture

4 Type designation

5Pressure rating PN

6 KVS coefcient

7 Perm. temperature in °C

8Set point range in bar

9Max. perm. differential pressure Δp in bar

10 Arrow indicating the direction of ow

12 3

6107

8 9

Fig.1: Nameplate

The nameplate of all sizes is afxed to the

body (see Fig.2).

Nameplate

position on

the body

Fig.2: Nameplate on the bodies

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