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EB 2540 EN Translation of original instructions Type 2404-2 Excess Pressure Valve with Pilot Valve Self-operated regulator for small set point ranges Edition May 2023...
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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.
Contents Safety instructions and measures ..............1-1 Notes on possible severe personal injury ............1-4 Notes on possible personal injury ..............1-5 Notes on possible property damage .............1-6 Markings on the device ................2-1 Nameplates ....................2-1 2.1.1 Nameplate of main valve................2-1 2.1.2 Actuator nameplate ..................2-2 2.1.3 Nameplate of pilot valve................2-2 2.1.4...
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Service work....................9-3 Ordering spare parts and operating supplies ..........9-4 Decommissioning ..................10-1 Removal ....................11-1 11.1 Removing the regulator from the pipeline ............11-1 11.2 Removing the actuator from the valve ............11-1 Repairs ....................12-1 12.1 Returning devices to SAMSON ..............12-1 Disposal ....................13-1 Certificates ....................14-1 Annex......................15-1 15.1 Tightening torques ..................15-1 15.2 Lubricants ....................15-1 15.3 Tools ......................15-1 15.4 Accessories ....................15-1...
Therefore, operators must ensure that the regulator is only used in operating conditions that meet the specifications used for sizing the regulator at the ordering stage. In case operators intend to use the controllers in applications or condi- tions other than those specified, 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. Î Refer to the technical data and nameplate for limits and fields of application as well as possible uses.
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− Safety harness, e.g. when working at height − Safety footwear, if applicable ESD (electrostatic discharge) footwear 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. Warning against residual hazards...
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Start-up and shutdown procedures fall within the scope of the operator's duties and, as such, 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.
Safety instructions and measures Referenced documentation The following documents apply in addition to these mounting and operating instructions: − Mounting and operating instructions for Type 2 N or 2 NI Strainer e.g. u EB 1015 e.g. Type 2406 Excess Pressure Valve u EB 2522 e.g. Type 2441 Pressure Reducing Valve u EB 2626-1 −...
Safety instructions and measures 1.2 Notes on possible personal injury WARNING Risk of personal injury through incorrect operation, use or installation as a result of information on the regulator being illegible. Over time, markings, labels and nameplates on the regulator may become covered with dirt or become illegible in some other way. As a result, hazards may go unno- ticed and the necessary instructions not followed.
Safety instructions and measures WARNING 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 deliv- ery note. Î Information on safe use of the part affected u www.samsongroup.com/en/ about-samson/material-compliance/reach-regulation/.
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Risk of excess pressure damaging plant sections due to construction-related seat leakage through the regulator. Î Always install a safety device (e.g. safety excess pressure valve or safety relief valve) in the plant. Note SAMSON's After-sales Service can support you concerning lubricant, tightening torques and tools approved by SAMSON. EB 2540 EN...
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Safety instructions and measures EB 2540 EN...
Markings on the device 2 Markings on the device Several nameplates are affixed to the device. The nameplates are used to identify the sepa- rate regulator components. 2.1 Nameplates 2.1.1 Nameplate of main valve Type 2406 Valve · DN 65 to 150 Max. perm. operating Pressure rating 16 Country of origin pressure at the actuator Perm. differential pressure 17 EAC, if applicable Material no./configuration ID 10 Perm. temperature 18 UKCA, if applicable Type...
Markings on the device 2.1.2 Actuator nameplate Actuator area 6.2 Max. perm. pressure at 12 UKCA, if applicable actuator Actuator model 13 Year of manufacture Valve size 2.1 Valve model 14 Month of manufacture Set point range Material number and device 15 CE marking index 10 Diaphragm material ID number 11 Country of origin...
Markings on the device 2.1.4 Nameplate of input pressure regulator Pressure rating: DIN: PN · ANSI: CL · JIS: K 2 Configuration ID (Var.-ID) and device index 3 Order number or year of manufacture 4 Type designation Thread size/valve size: DIN: DN · ANSI: NPS · JIS: DN … A/B Flow coefficient: DIN: K · ANSI: C · JIS: C Perm. temperature: DIN: °C · ANSI: °F · JIS: °C/°F Set point range: DIN: bar · ANSI: psi · JIS: bar/psi Max. perm. differential pressure Δp: DIN: bar · ANSI: psi · JIS: bar/psi 10 Arrow indicating the direction of flow Fig. 2-4: Nameplate of Type 2441 Input Pressure Regulator EB 2540 EN...
Markings on the device 2.2 Location of the nameplates Location of the nameplate on the main valves Location of the nameplate on the input pressure regulator Location of the nameplate on the pilot valve Fig. 2-5: Nameplates of the main valves, pilot valve and assembled regulator EB 2540 EN...
Markings on the device 2.3 Material identification 2.3.3 Type 2420 Actuator number Specifying the material number, you can contact us to find out which material is used. 2.3.1 Type 2406 as main It is specified on the nameplate in the 'MNo.' field (3). For more details on the nameplate, valve see section 2.1.2. See the nameplate (11 for DIN/ANSI ver- 2.3.4 Type 2406 Pilot Valve sion, body material) for the material used. Specifying the material number, you can See the nameplate (11 for DIN/ANSI ver- contact us to find out more details.
Design and principle of operation 3 Design and principle of oper- Note ation Optionally, the outlet ( NPT) of the needle valve (4) can be routed to the downstream Î See Fig. 3-1 pressure (p ) side of the main valve. The following components interact to regu- late the pressure of the inert gas.
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Design and principle of operation Pilot valve Needle valve (lead- sealed setting) Input pressure regulator Main valve Tank To atmosphere or recovered for processing Inert gas Main valve Set point adjuster (screw Supply pressure SW 27/1 “) 1.1 Closing spring Upstream pressure (blanketing gas pressure) 2.4 Control line Operating diaphragm...
We recommend installing a Strainers strainer (e.g. SAMSON Type 2 NI) upstream We recommend installing a SAMSON of the input pressure regulator (u EB 1015). strainer (2) upstream of the input pressure...
(see the 'Markings on the device' sec- Noise emissions tion). SAMSON is unable to make general state- ments about noise emissions. The noise emis- Note sions depend on the regulator version, plant More information is available in Data Sheet facilities, process medium and operating u T 2540.
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Design and principle of operation Table 3-1: Technical data for main valve · All pressures in bar (gauge) Type 2406 as main valve, balanced by a diaphragm NPS 2½ NPS 3 NPS 4 – NPS 6 Valve size DN 65 DN 80 DN 100 DN 125 DN 150 · Pressure rating Class 125, 150, 300 PN 16, 40 coefficients...
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Design and principle of operation Table 3-2: Technical data for pilot valve · All pressures in bar (gauge) Type 2406 Pilot Valve Connection ½ NPT Pressure rating Class 300 coefficient coefficient 0.075 to 0.2 psi/ 0.15 to 0.45 psi/ 0.35 to 0.9 psi/ 0.75 to 3 psi/ Set point ranges 5 to 15 mbar 10 to 30 mbar 25 to 60 mbar 50 to 200 mbar Actuator area 100 in²/640 cm²...
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Design and principle of operation Table 3-4: Materials for main valve · Material numbers according to ASTM and DIN EN Type 2406 as main valve A126B, A216 WCC, A351 CF8M · EN-GJL-250, 1.0619, Body 1.4408 Valve seat 1.4404/316L Plug 1.4404/316L Plug seal EPDM · NBR · FKM Operating diaphragm, balancing EPDM · NBR · FKM 4) diaphragm Internal parts, guiding parts 1.4404/316L Diaphragm cases...
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Design and principle of operation Table 3-5: Materials for pilot valve · Material numbers according to ASTM and DIN EN Pilot valve Type 2406 1) Body A216 WCC · A351 CF8M Valve seat 1.4404/316L Plug 1.4404/316L Plug seal EPDM · NBR · FKM Operating diaphragm EPDM · FKM Internal parts, guiding parts 1.4404/316L Set point spring 1.4310 Versions for sour gas service (NACE) possible...
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Design and principle of operation Dimensions · NPS 2½ to 6/DN 65 to 150 Table 3-8: Dimensions · NPS 2½ to 6 (DN 65 to 150) (see Fig. 3-3) NPS 2½ NPS 3 NPS 4 NPS 6 – Type 2404-2 DN 65 DN 80 DN 100 DN 125 DN 150 Class 125 and 10.9“/ 11.7“/ 13.9“/ 17.75“/ – 276 mm 298 mm 352 mm 451 mm...
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Design and principle of operation Dimensions · DN 200 to 400 · NPS 8 to 16 Table 3-9: Dimensions · DN 200 to 400 · NPS 8 to 16 (see Fig. 3-6 and Fig. 3-7) NPS 8 NPS 10 NPS 12 NPS 16 Type 2404-2 DN 200 DN 250 DN 300 DN 400 Class 125 and 21.4“/543 mm 26.5“/673 mm 28.9“/736 mm 40“/1016 mm Class 300 22.4”/568 mm 27.9“/708 mm –...
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Design and principle of operation ØD Dimensions Pipe Ø ½“ Control line for upstream pressure p Pipe Ø ½“ Supply pressure p Pipe Ø ½“ Supply pressure p Fig. 3-3: DN 65 to 100/NPS 2½ to 4 · Versions with seal/diaphragm made of EPDM/NBR/FKM EB 2540 EN 3-11...
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Design and principle of operation ØD Dimensions Pipe Ø ½“ Control line for upstream Pipe Ø ½“ pressure p Supply pressure p Pipe Ø ½“ Supply pressure p Fig. 3-4: DN 125 to 150/NPS 6 · Versions with seal/diaphragm made of EPDM/NBR 3-12 EB 2540 EN...
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Design and principle of operation ØD Dimensions Pipe Ø ½“ Pipe Ø ½“ Control line for upstream Supply pressure p pressure p Pipe Ø ½“ Supply pressure p Fig. 3-5: DN 125 to 150/NPS 6 · Versions with seal/diaphragm made of FKM EB 2540 EN 3-13...
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Design and principle of operation ØD Dimensions Pipe Ø ½“ Control line for upstream pressure p Pipe Ø ½“ Supply pressure p Pipe Ø ½“ Supply pressure p Pipe Ø ½“ Control line for upstream pressure p Fig. 3-6: DN 200 to 400/NPS 8 to 16 · Versions with seal/diaphragm made of EPDM/NBR 3-14 EB 2540 EN...
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Design and principle of operation ØD Dimensions Pipe Ø ½“ Control line for upstream Pipe Ø ½“ pressure p Supply pressure p Pipe Ø ½“ Supply pressure p Pipe Ø ½“ Control line for upstream pressure p Fig. 3-7: DN 200 to 300/NPS 8 to 12 · Versions with seal/diaphragm made of FKM EB 2540 EN 3-15...
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Design and principle of operation 3-16 EB 2540 EN...
2. Check the shipment for transportation Î Dispose and recycle the packaging in ac- damage. Report any damage to cordance with the local regulations. SAMSON and the forwarding agent (refer to delivery note). 3. Determine the weight and dimensions of the units to be lifted and transported in order to select the appropriate lifting equipment and lifting accessories. Refer...
Shipment and on-site transport 4.3 Transporting and lifting the WARNING regulator Risk of personal injury due to the regulator tipping. Î Observe the regulator's center of gravity. DANGER Î Secure the regulator against tipping over Danger due to suspended loads falling. or turning.
Shipment and on-site transport 4.3.2 Lifting the regulator 5. After installation in the pipeline, check whether the regulator flanges are bolted To install a large regulator into the pipeline, tight. use lifting equipment (e.g. crane or forklift) 6. Remove slings. to lift it. Lifting instructions Î Use a hook with safety latch to secure the slings from slipping off the hook during lifting and transporting (see Fig. 4-1).
Î To keep elastomers in shape and to pre- Î Avoid long storage times. vent cracking, do not bend them or hang Î Contact SAMSON in case of different them up. storage conditions or longer storage Î Store elastomers away from lubricants, times.
Î Contact SAMSON if the mounting posi- nel. tion is not as specified above. Plant operators must ensure that, after instal- lation of the device, the operating personnel...
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Tank Shut-off valve 4.1 Input pressure regulator Strainer 4.2 Pilot valve Pressure gauge (storage tank) 4.3 Main valve with actuator (when mounted) Type 2404-2 Excess Pressure Valve 4.4 Needle valve (lead-sealed setting) Fig. 5-2: Type 2404-2 (installation example) EB 2540 EN...
Risk of regulator damage due to the use of the valve. unsuitable tools. Proceed as follows: Î Only use tools approved by SAMSON (see 'Tools' in Annex). Î Lay out the necessary material and tools to have them ready during installation work.
Installation 5.3.1 Installing the regulator 5.3.2 Cleaning the pipeline Install the regulator in such a way that it is We recommend additionally flushing the still easily accessible after the plant is com- pipeline without the installed regulator be- pleted to facilitate maintenance or revision fore start-up.
Flying projectile fragments or the gloves. release 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.
1. Start up the plant and adjust the set point The plant operator is responsible for (see the 'Start-up' section). performing the pressure test. SAMSON's 2. Shut down the plant again and let it heat After-sales Service can support you to plan up until the condensation water has and perform a pressure test for your plant.
Start-up 6 Start-up DANGER The work described in this section is only to Risk of personal injury due to process me- be performed by personnel appropriately dium escaping. qualified to carry out such tasks. Î Do not start up the regulator until all parts have been mounted. WARNING Before start-up or putting the valve back into Risk of burn injuries due to hot or cold com-...
Start-up 6.1 Start-up and putting the device back into operation 1. Depending on the field of application, allow the regulator to cool down or warm up to reach ambient temperature before start up. 2. Slowly open the shut-off valve in the sup- ply pipeline. Slowly opening these valves prevents a sudden surge in pressure and high flow velocities which can damage the regulator.
Operation 7 Operation 7.1 Adjusting the set point Immediately after completing start-up or Adjust the set point by tensioning the set placing the regulator back into service (see point springs (2.1) at the set point adjuster the 'Start-up' section), the regulator is ready (2.3) (adjusting screw) on the pilot valve (2).
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Operation Note Do not unscrew the adjusting screw com- pletely on turning it counterclockwise (). Do not screw the adjusting screw as far as it will go on turning it clockwise (). Other- wise the travel will be restricted or the valve will even remain stuck in the closed position.
Malfunctions 8 Malfunctions 8.1 Troubleshooting Malfunction Possible reasons Recommended action Note Malfunction only occurs when the consumer is closed or during low load: Î Remove valve from the Install a shut-off valve instead pipeline and clean seat Pilot valve of the pilot valve. If the main and plug. Renew plug, if Leak between seat and valve closes when the shut-off...
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Malfunctions Malfunction Possible reasons Recommended action Note Install a shut-off valve instead Upstream of the pilot valve. If the main pressure rises Î Replace the balancing Balancing diaphragm of valve does not close when the far above the diaphragm with a new the main valve defective. shut-off valve is closed, the adjusted set one.
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If this is the case, send a sketch where the regulator is which may lead to an of the plant to SAMSON for a installed are not suitable instable control process. thorough analysis. for the regulator.
1. Close the shut-off valves to stop the pro- cess medium from flowing through the regulator. 2. Perform troubleshooting (see sec- tion 8.1). 3. Rectify those malfunctions that can be remedied based on the instructions provided here. Contact SAMSON's After-sales Service in all other cases. Putting the device back into operation after a malfunction See the 'Start-up' section. EB 2540 EN...
Risk of regulator damage due to the use of ries. unsuitable tools. Î Allow components and pipelines to cool Î Only use tools approved by SAMSON down or warm up to the ambient tem- (see 'Tools' in Annex). perature. Î Wear protective clothing and safety NOTICE gloves.
The regulator was checked by SAMSON before it left the factory. 1. Lay out the necessary material and tools − Certain test results certified by SAMSON to have them ready for the service work. lose their validity when the regulator is 2.
Servicing 9.2 Installing the regulator 9.3 Service work after service work Î Before performing any service work, preparations must be made to the regu- Î Put the regulator back into operation (see lator (see section 9.1). the 'Start-up' section). Make sure the re- quirements and conditions for start-up or Î After all service work is completed, check putting the valve back into operation are the regulator before putting it back into met.
Servicing 9.4 Ordering spare parts and operating supplies Contact your nearest SAMSON subsidiary or SAMSON's After-sales Service for infor- mation on spare parts, lubricants and tools. Spare parts Contact SAMSON's After-sales Service for more information on spare parts. Lubricants Contact SAMSON's After-sales Service for more information on lubricants.
Decommissioning 10 Decommissioning 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 qualified to carry out such tasks. discharged. Î Do not loosen the control line while the valve is pressurized.
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Decommissioning To decommission the regulator for service work or disassembly, proceed as follows: 1. Close the shut-off valve (1). 2. Depressurize the plant. 3. Completely drain the pipelines and valve. 4. If necessary, allow the pipeline and reg- ulator components to cool down or warm up to the ambient temperature. 10-2 EB 2540 EN...
Removal 11 Removal 11.1 Removing the regulator from the pipeline The work described in this section is only to be performed by personnel appropriately 1. Support the regulator to hold it in place qualified to carry out such tasks. when separated from the pipeline (see the 'Shipment and on-site transport' sec- WARNING tion).
Î Do not perform any repair work on your 3. Fill in the Declaration on Contamination. own. The declaration form can be download- Î Contact SAMSON's After-sales Service ed from our website at for service and repair work. u www.samsongroup.com > SERVICE & SUPPORT > After-sales Service. 4. Continue as described on our website at u www.samsongroup.com >...
Disposal 13 Disposal SAMSON is a producer registered at the following European institution u https://www.ewrn.org/ national-registers/national- registers. WEEE reg. no.: DE 62194439/FR 025665 Î Observe local, national and internation- al refuse regulations. Î Do not dispose of components, lubricants and hazardous substances together with your other household waste. Note We can provide you with a recycling passport according to PAS 1049...
Certificates 14 Certificates The EU declarations of conformity are in- cluded on the next pages: − EU declaration of conformity in compli- ance with Pressure Equipment Directive 2014/68/EU on page 14-2. EB 2540 EN 14-1...
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DIN EN, body, EN-GJS-400-18-LT and CC499K, DN 50, PN 25, fluids G2, L2, L1 2447 (44-7) 2448 (44-8) 2449 (44-9) Revision 00 Classification: Public · SAMSON AKTIENGESELLSCHAFT · Weismuellerstrasse 3 · 60314 Frankfurt am Main, Germany Page 1 of 3 14-2 EB 2540 EN...
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Liquids according to Article 4(1)(c.ii) Gases according to Article 4(1)(c.i), second indent Liquids according to Article 4(1)(c.ii), second indent Revision 00 Classification: Public · SAMSON AKTIENGESELLSCHAFT · Weismuellerstrasse 3 · 60314 Frankfurt am Main, Germany Page 2 of 3 EB 2540 EN 14-3...
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Norbert Tollas i.V. Peter Scheermesser Senior Vice President Director Global Operations Product Maintenance & Engineered Products Revision 00 Classification: Public · SAMSON AKTIENGESELLSCHAFT · Weismuellerstrasse 3 · 60314 Frankfurt am Main, Germany Page 3 of 3 14-4 EB 2540 EN...
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ANSI, body, A216 WCC and A351 CF8M, NPS 2½-6, Class 150, all fluids ANSI, body, A216 WCC and A351 CF8M, NPS 1½-6, Class 300, all fluids Revision 00 Classification: Public · SAMSON AKTIENGESELLSCHAFT · Weismuellerstrasse 3 · 60314 Frankfurt am Main, Germany Page 1 of 3 EB 2540 EN...
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DIN EN, body, EN-GJS-400-18-LT, DN 100-150, PN 25, fluids G2, L2, L1 DIN EN, body, 1.0619, DN 100-250, PN 16, all fluids Revision 00 Classification: Public · SAMSON AKTIENGESELLSCHAFT · Weismuellerstrasse 3 · 60314 Frankfurt am Main, Germany Page 2 of 3 14-6...
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Norbert Tollas i.V. Peter Scheermesser Senior Vice President Director Global Operations Product Maintenance & Engineered Products Revision 00 Classification: Public · SAMSON AKTIENGESELLSCHAFT · Weismuellerstrasse 3 · 60314 Frankfurt am Main, Germany Page 3 of 3 EB 2540 EN 14-7...
Tightening torque in Nm Adjusting screw (2.3) SW 27 – Control line connection – 15.2 Lubricants SAMSON's After-sales Service can support you concerning lubricants and sealants ap- proved by SAMSON. 15.3 Tools SAMSON's After-sales Service can support you concerning tools approved by SAMSON.
(see nameplates). You can reach our after-sales service at − Model number or material number aftersalesservice@samsongroup.com. − Supply pressure p, upstream pressure Addresses of SAMSON AG and its subsid- (inert gas pressure) p and downstream iaries pressure p The addresses of SAMSON, its subsidiaries, −...
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EB 2540 EN EB 2540 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...