Samson 44-7 Mounting And Operating Instructions
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Samson 44-7 Mounting And Operating Instructions

Samson 44-7 Mounting And Operating Instructions

Excess pressure valve
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EB 2723 EN
Translation of original instructions
Type 44-7 Excess Pressure Valve
Red brass body with screwed ends
Type 44-7 Excess Pressure Valve
Type 44-4 Safety Excess Pressure Valve (SEV)
Self-operated Pressure Regulators
Edition May 2023

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  • Page 1 EB 2723 EN Translation of original instructions Type 44-7 Excess Pressure Valve Red brass body with screwed ends Type 44-7 Excess Pressure Valve Type 44-4 Safety Excess Pressure Valve (SEV) Self-operated Pressure Regulators Edition May 2023...
  • Page 2 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. The images shown in these instructions are for illustration purposes only. The actual product may vary.

  • Page 3: Table Of Contents

    Contents Safety instructions and measures ..............5 Notes on possible severe personal injury ............7 Notes on possible personal injury ..............8 Notes on possible property damage ..............9 Warnings on the regulator ................11 Markings on the device ................11 Regulator nameplate ..................11 Location of the nameplate ................11 Material identification number ..............12 Warning .....................12 Design and principle of operation ..............12...
  • Page 4 Contents Servicing.....................28 Cleaning and replacing the seat and plug ............29 Replacing the operating diaphragm ..............31 Replacing the set point springs ..............33 Tightening torques and lubricant ..............34 Preparation for return shipment ..............35 Ordering spare parts and operating supplies ..........35 Malfunctions ....................36 Decommissioning and removal ..............39 10.1 Decommissioning ..................39...

  • Page 5: Safety Instructions And Measures

    SAMSON. SAMSON does not assume any liability for damage resulting from the failure to use the device for its intended purpose or for damage caused by external forces or any other external factors.
  • Page 6 Î Check with the plant operator for details on further protective equipment. Revisions and other modifications Revisions, conversions or other modifications 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. Fur- thermore, the product may no longer meet the requirements for its intended use.

  • Page 7: Notes On Possible Severe Personal Injury

    Safety instructions and measures are not part of these mounting and operating instructions. SAMSON is unable to make any statements about these procedures since the operative details (e.g. differential pressures and temperatures) vary in each individual case and are only known to the operator.

  • Page 8: Notes On Possible Personal Injury

    Î Before starting any work on the set point springs, relieve the compression from the preloaded springs. Î Only use the SAMSON disassembly tool (1280-4052). Crush hazard arising from moving parts. The regulator contains moving parts (actuator and plug stem), which can injure hands or fingers if inserted into the valve.

  • Page 9: Notes On Possible Property Damage

    Î Wear protective clothing and safety gloves. Damage to health relating to the REACH regulation. If a SAMSON device contains a substance listed as a substance of very high concern on the candidate list of the REACH regulation, this is indicated on the SAMSON delivery note.
  • Page 10 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 surfaces. Î Only use lubricants approved by SAMSON. Risk of leakage and regulator damage due to excessively high or low tightening torques.

  • Page 11: Warnings On The Regulator

    Markings on the device 1.4 Warnings on the regulator Warning Meaning of the warning Location on the device symbols Warning to indicate that the set point springs are WARNING Disassembly of loaded. spring only with There is a risk of serious head or face injury due to the suitable tool.

  • Page 12: Material Identification Number

    They open when the upstream tion 2.1). pressure rises above the adjusted set point. The Type 44-4 and Type 44-7 Excess Pres- Process medium and scope of application sure Valves mainly consist of the valve (1) The excess pressure valve and safety excess...
  • Page 13 Spring plate Diaphragm plate Plug with seal Inspection bore Set point adjuster O-rings 3.1 Balancing piston Actuator housing Control line Fig. 3: Functional diagram of Type 44-7 Excess Pressure Valve as well as Type 44-4 Safety Excess Pressure Valve (SEV) EB 2723 EN...
  • Page 14 The test mark is available on request. With seals made of FKM Temperature range The Type 44-4 and Type 44-7 Regulators are designed for a temperature range from 0 to +150 °C. Leakage class All regulators have the leakage class I ac- cording to IEC 60534-4.
  • Page 15 Design and principle of operation Table 1: Technical data · All pressures in bar (gauge) Regulator Excess pressure valve 44-7 44-4 (SEV) Red brass body Male thread DN 15, 20, 25, 32, 40 and 50 Connection Spheroidal graphite iron body Flanges DN 32, 40 and 50 Pressure rating PN 25...
  • Page 16 26.8 33.7 42.0 48.0 60.0 Connection R G ¾ G 1 G 1¼ G 1¾ G 2 G 2½ Width across flats SW Type 44-7  2)  2) Height H Type 44-4  1)  1) Height H1 Height H2 Actuator housing ØD Version with welding ends Length L1 Weight kg (approx.) 11.8...
  • Page 17 Dimensional drawings Version with welding ends Type 44-7 · Body: CC499K Type 44-4 · Body: CC499K R Ød Ød ØD ØD Version with flanged valve body Type 44-4 and Type 44-7 Body: spheroidal graphite iron Version with threaded ends  1) Fig. 4: Dimensions DN 32, 40 and 50 EB 2723 EN...

  • Page 18: Measures For Preparation

    − Observe the storage instructions. note. − Avoid long storage times. 2. Check the shipment for transportation − Contact SAMSON in case of different damage. Report any damage to storage conditions or longer storage times. SAMSON and the forwarding agent (refer to delivery note).
  • Page 19 Protection of a house substation with more detailed storage instructions on re- SSV and SEV quest. Shut-off valve Excess pressure valve Upstream pressure gauge Downstream pressure gauge Strainer (Type 44-7 only) Fig. 5: Pressure control with Type 44-7 (installation example) EB 2723 EN...

  • Page 20: Mounting

    Mounting 5. Mounting 5.1 Mounting positions Install Type 44-4 and Type 44-7 Regulators NOTICE NOTICE with the actuator housing suspended down- Risk of overheating due to excessive ward in horizontal pipelines. ambient temperatures or insufficient heat Installation conditions dissipation when components are insulated.

  • Page 21: Additional Fittings

    For example, pressures prevailing in the plant (see Fig. 5). the SAMSON Type 1 NI Strainer is suitable (u T 1010). The following points must be observed when installing the strainer: −...

  • Page 22: Preparation For Installation

    Mounting 5.3 Preparation for installation 5.3.1 Cleaning the pipeline Before mounting, make sure the following We recommend additionally flushing the conditions are met: pipeline without an installed regulator over a time period of several minutes before start- − The regulator is clean. up.

  • Page 23: Installation

    Mounting 5.4 Installation 5.4.1 Installing the regulator SAMSON regulators are delivered as as- 1. Close the shut-off valves upstream and sembled units. The activities listed below are downstream of the regulator while the necessary for installation and before start-up regulator is being installed.

  • Page 24: Testing The Regulator

    Flying projectile fragments or the re- gloves. lease of process medium under pressure can cause serious injury or even death. SAMSON regulators are delivered ready for Before working on the regulator: use. To test the regulator functioning before Î Depressurize all plant sections concerned start-up or putting back the regulator into and the regulator.

  • Page 25: Pressure Test

    Note The plant operator is responsible for 5.6 Insulation performing the pressure test. SAMSON's After-sales Service can support you to plan To insulate cold systems, we recommend first and perform a pressure test for your plant.

  • Page 26: Start-Up

    Start-up 6. Start-up WARNING The work described in this section is only to Risk of personal injury due to pressurized be performed by personnel appropriately components and process medium being dis- qualified to carry out such tasks. charged. Î Do not loosen the control line while the valve is pressurized.

  • Page 27: Start-Up And Putting The Device Back Into Operation

    Operation 6.1 Start-up and putting the 7. Operation device back into operation 7.1 Adjusting the set point 1. Depending on the field of application, allow the regulator to cool down or Î See Fig. 3 warm up to reach ambient temperature Adjust the required set point by turning the before start up.

  • Page 28: Servicing

    While working on the regulator, residual NOTICE process medium can escape and, depending Risk of regulator damage due to the use of on its properties, may lead to personal in- unsuitable tools. jury, e.g. (chemical) burns. Only use tools approved by SAMSON. EB 2723 EN...

  • Page 29: Cleaning And Replacing The Seat And Plug

    − Before starting any work on the springs, relieve the compression from the preloaded Note springs. The regulator was checked by SAMSON − Only use the SAMSON disassembly tool before delivery. (1280-4052). − Certain test results certified by SAMSON lose their validity when the regulator is opened.
  • Page 30 4. Unscrew the control line (11). 5. Unscrew the body stopper (1.1). 6. Remove the seal (1.2). Note SAMSON's After-sales Service can support 7. Unscrew the body screws (13) and take you concerning lubricant, tightening torques off the actuator housing (6) together with and tools approved by SAMSON.

  • Page 31: Replacing The Operating Diaphragm

    4. Place the plug (3) onto the plug stem and − Only use the SAMSON disassembly tool screw on the plug nut (3.2). Observe the (1280-4052). tightening torques specified in sec- tion 8.4.
  • Page 32 (8) by turning the set specified in section 8.4. point adjuster (10) counterclockwise (). 6. Use the SAMSON disassembly tool to 3. Remove the device from the pipeline screw the valve body (1) together with 4. Unscrew the control line (11).

  • Page 33: Replacing The Set Point Springs

    (10) counterclockwise (). springs. 3. Remove the device from the pipeline − Only use the SAMSON disassembly tool 4. Unscrew the control line (11). (1280-4052). 5. Use the SAMSON disassembly tool to unscrew the set point adjuster (10) from the diaphragm stem (7).

  • Page 34: Tightening Torques And Lubricant

    Servicing Note Change the nameplate and configuration ID after changing the set point range. 8.4 Tightening torques and lubricant Î See Fig. 3 Component Valve size Tightening torque in Nm DN 15 to 25 Stopper (1.1) DN 32 to 50 DN 15 to 25 Seat (2) DN 32 to 50 DN 15 to 25 Plug nut (3.2)

  • Page 35: Preparation For Return Shipment

    Defective devices can be returned to SAM- Contact your nearest SAMSON subsidiary SON for repair. Proceed as follows to return or SAMSON's After-sales Service for infor- devices to SAMSON: mation on spare parts, lubricants and tools. 1. Put the regulator out of operation (see Spare parts section 10.1).

  • Page 36: Malfunctions

    For troubleshooting, the condi- tions, such as installation, process medium, temperature and pressure conditions, must be taken into account. SAMSON's After-sales Service can help during troubleshooting. Further information is available in section 11.1. We recommend removing the regulator from the pipeline before repairing it.
  • Page 37 Malfunctions Table 5: Troubleshooting Malfunction Possible reasons Recommended action Insufficient pressure pulses on the Î Connect the control line on site for regulators operating diaphragm. with external control line. Î Clean the control line and screw fittings. Pressure tapped at the wrong Î...
  • Page 38 NOTICE Risk of TÜV approval (based on AGFW worksheet FW 506) for Type 44-4 becoming void. Consult SAMSON's After-sales Service before you change parts or perform service or repair work on TÜV-tested Type 44-4 Regulators. EB 2723 EN...

  • Page 39: Decommissioning And Removal

    Decommissioning and removal Decommissioning and 10.1 Decommissioning removal To decommission the regulator for service and repair work or disassembly, proceed as follows: DANGER Risk of bursting in pressure equipment. 1. Close the shut-off valve on the upstream Regulators and pipelines are pressure equip- side of the regulator.

  • Page 40: Disposal

    Decommissioning and removal 10.2 Disposal We are registered with the German national register for waste electric equipment (stiftung ear) as a producer of electrical and electronic equipment, WEEE reg. no.: DE 62194439 Î Observe local, national and internation- al refuse regulations. Î...

  • Page 41: Annex

    E-mail address You can reach our after-sales service at aftersalesservice@samsongroup.com. Addresses of SAMSON AG and its subsid- iaries The addresses of SAMSON, its subsidiaries, representatives and service facilities worldwide can be found on our website (u www.samsongroup.com) or in all...
  • Page 42 Annex DN 15 to 25 Position numbers Plug Coupling nut Restriction assembly Stopper Screw plug Body Threaded seat Lock nut 70…78 Compression spring Diaphragm stem Diaphragm plate 70...78 Spring plate Washer Diaphragm case assembly Pipe Diaphragm Screw Axial needle bearing Screw fitting O-ring O-ring O-ring...
  • Page 43 Annex DN 32 to 50 Position numbers Plug Coupling nut Restriction assembly Stopper Screw plug Body Threaded seat Lock nut 70…78 Compression spring Diaphragm stem Diaphragm plate Spring plate Washer Diaphragm case assembly Pipe Diaphragm 70...78 Screw Axial needle bearing Screw fitting O-ring O-ring O-ring...

  • Page 44: Certificates

    Annex 11.3 Certificates The EU declarations of conformity are in- cluded on the next pages. EB 2723 EN...
  • Page 45 Annex Modul H/Module H, Nr./No. / N° CE-PED-H-SAM 001-13-DEU-rev-A SAMSON erklärt in alleiniger Verantwortung für folgende Produkte:/For the following products, SAMSON hereby declares under its sole responsibility: Ventile für Druck-, Differenzdruck-, Temperatur- und Volumenstromregler/Valves for pressure, temperature, flowregulators and differential pressure regulators Typ 2336, 2373, 2375, 44-1B, 44-2, 44-3, 44-4, 44-6B, 44-9, 45-1, 45-2, 45-3, 45-4, 45-6, (Erz.-Nr.
  • Page 46 2333 (Erz.-Nr./Model No. 2333), 2334 (2334), 2335 (2335), 2336, 2373, 2375, 44-0B, 44-1B, 44-2, 44-3, 44-6B, 44-7, 44-8, 45-1, 45-2, 45-3, 45-4, 45-5, 45-6, 2468, 2478 (2720), 45-9, 46-5, 46-6, 46-7, 46-9, 47-1, 47-4, 47-5, 47-9, 2487, 2488, 2489, 2491, 2494, 2495 (2730), 2405, 2406, 2421 (2811), 2392, 2412 (2812), 2114 (2814), 2417 (2817), 2422 (2814), 2423 (2823) die Konformität mit nachfolgender Anforderung/the conformity with the following requirement.
  • Page 47 Annex Modul D/Module D, Nr./No. / N° CE-0062-PED-D-SAM 001-16-DEU-rev-A SAMSON erklärt in alleiniger Verantwortung für folgende Produkte:/For the following products, SAMSON hereby declares under its sole responsibility: Sicherheitsüberströmventil SÜV 44-4 (2720-03)/Safety Excess Pressure Valve SEV 44-4 (2720-03) die Konformität mit nachfolgender Anforderung/the conformity with the following requirement.
  • Page 48 Annex Modul D/Module D, Nr./No. / N° CE-0062-PED-D-SAM 001-16-DEU-rev-A SAMSON erklärt in alleiniger Verantwortung für folgende Produkte:/For the following products, SAMSON hereby declares under its sole responsibility: Sicherheitsüberströmventil SAV 44-8 (2720-02)/Safety Excess Pressure Valve SSV 44-8 (2720-02) die Konformität mit nachfolgender Anforderung/the conformity with the following requirement.
  • Page 49 EB 2723 EN...
  • Page 50 EB 2723 EN SAMSON AKTIENGESELLSCHAFT Weismüllerstraße 3 · 60314 Frankfurt am Main, Germany Phone: +49 69 4009-0 · Fax: +49 69 4009-1507 samson@samsongroup.com · www.samsongroup.com...

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