Samson 33-1 Mounting And Operating Instructions
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Samson 33-1 Mounting And Operating Instructions

Safety shut-off valve with pressure reducing valve self-operated pressure regulators
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EB 2551-1 EN
Translation of original instructions
Type 33-1 Safety Shut-off Valve with Pressure Reducing Valve
Self-operated Pressure Regulators
Edition November 2019

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Summary of Contents for Samson 33-1

  • Page 1 EB 2551-1 EN Translation of original instructions Type 33-1 Safety Shut-off Valve with Pressure Reducing Valve Self-operated Pressure Regulators Edition November 2019...
  • 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 ..............1-1 Notes on possible severe personal injury ............1-4 Notes on possible personal injury ..............1-4 Notes on possible property damage .............1-6 Markings on the device ................2-1 Nameplate ....................2-1 Nameplate position ..................2-1 Material numbers ..................2-1 Design and principle of operation ...............3-1 3.1 Additional fittings ..................3-3 Technical data ....................3-4...
  • Page 4 Replacing the operating diaphragm .............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 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 Lubricant ....................15-1 15.3...

  • Page 5: Safety Instructions And Measures

    In case operators intend to use the regulators in other applications or conditions than 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.
  • Page 6 Hazards resulting from the special working conditions at the installation site of the regulator must be identified in a risk assessment and prevented through the corresponding safety in- structions drawn up by the operator. We also recommend checking the hazards posed by the process medium being used (e.g. u GESTIS (CLP) hazardous substance database). Î Observe safety measures for handling the device as well as fire prevention and explosion protection measures. Safety features The Type 33-1 Regulator is a safety shut-off valve (SSV) with pressure reducing valve. When relieved of pressure, the regulator is closed by the force of the set point springs in the actua- tor. EB 2551-1 EN...
  • Page 7 Safety instructions and 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.

  • Page 8: Notes On Possible Severe Personal Injury

    Safety instructions and measures 1.1 Notes on possible severe personal injury DANGER Risk of bursting in pressure equipment. Regulators and pipelines are pressure equipment. Impermissible pressure or improper opening can lead to regulator components bursting. Î Observe the maximum permissible pressure for regulator and plant. Î...
  • Page 9 Î Wear 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 indi- cated on the SAMSON delivery note.

  • Page 10: Notes On Possible Property Damage

    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. Î Flush the pipelines before start-up. Note SAMSON's After-sales Service can support you concerning lubricants approved by SAMSON. EB 2551-1 EN...

  • Page 11: Markings On The Device

    Fig. 2-1: Nameplates of regulator parts 2.3 Material numbers 2.2 Nameplate position The material designation can be found on the nameplate (7, body material) or you can contact us (the configuration ID specification Nameplate is needed) to find out which material is used. position The configuration ID is specified on the nameplate (3, configuration ID). For more details on the nameplate, see section 2.1. Fig. 2-2: Nameplate of Type 33-1 Regulator EB 2551-1 EN...
  • Page 12 Markings on the device EB 2551-1 EN...

  • Page 13: Design And Principle Of Operation

    (1) to be closed by Î See Fig. 3-1 the set point springs (7). The Type 33-1 Safety Shut-off Valve (SSV) Upon failure of the operating diaphragm (6), consists of the main valve with actuator and the safety shut-off valve closes and the pres- the pilot valve attached to it.
  • Page 14 Design and principle of operation Main valve Operating diaphragm 8.3 Set point springs Seat Set point springs Set point adjuster Plug Pilot valve 10 Control line for upstream pressure p Plug stem 8.1 Filter 11 Control line for downstream pressure p Balancing bellows 8.2 Restriction 12 Control line for control pressure (p...

  • Page 15: Additional Fittings

    Any impurities carried along by the process medium may impair the proper functioning Strainers of the regulator. We recommend installing a We recommend installing a SAMSON strainer (e.g. SAMSON Type 2 NI) upstream strainer (2) upstream of the regulator. It pre- of the pressure reducing valve (u EB 1015).

  • Page 16: Technical Data

    (u T 2551-1). Leakage class Noise emission The soft-seated regulator has the leakage class IV according to IEC 60534-4. SAMSON is unable to make general state- ments about noise emissions. The noise emis- sions depend on the regulator version, plant facilities, process medium and operating conditions. EB 2551-1 EN...
  • Page 17 DN 65 DN 80 DN 100 DN 125 DN 150 DN 200 DN 250 coefficient Value at K  1) value 0.40 0.35 0.30 Despite installing a strainer upstream of the regulator, dirt particles may impair the valve shut-off depending on the size of the strainer mesh. On using the SAMSON Type 2 NI Strainer, the maximum leakage rate may correspond to the specified value at K  0.3 due to the clogging up of the valve. This value is then significant on sizing the safety valve or safety excess pressure valve in the plant. EB 2551-1 EN...
  • Page 18 Design and principle of operation Table 3-3: Materials · Material numbers according to DIN EN Valve Pressure rating PN 16 PN 16 · PN 25 PN 16 · PN 25 · PN 40 Cast iron Spheroidal graphite iron Cast steel Body EN-GJL-250 EN-GJS-400-18-LT 1.0619  1) Seat Stainless steel 1.4006 DN 65 to 100 Stainless steel 1.4006 Plug with EPDM seal DN 125 to 250...
  • Page 19 Design and principle of operation Dimensional drawings ØD Fig. 3-3: Dimensions EB 2551-1 EN...
  • Page 20 Design and principle of operation EB 2551-1 EN...

  • Page 21: Shipment And On-Site Transport

    2. Check the shipment for transportation from entering the regulator. damage. Report any damage to Î Dispose and recycle the packaging in SAMSON and the forwarding agent accordance with the local regulations. (refer to delivery note). 3. Determine the weight and dimensions of...

  • Page 22: Transporting And Lifting The Regulator

    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 Risk due to suspended loads falling. or turning.

  • Page 23: Lifting The Regulator

    Shipment and on-site transport 4.3.2 Lifting the regulator 2. Carefully lift the regulator. Check wheth- er the lifting equipment and accessories To install a large regulator into the pipeline, can bear the weight. use lifting equipment (e.g. crane or forklift) 3.

  • Page 24: Storing The Regulator

    Î Observe the storage instructions. Î Do not damage the corrosion protection Î Avoid long storage times. (paint, surface coatings). Repair any Î Contact SAMSON in case of different damage immediately. storage conditions or long storage peri- Î Protect the regulator against moisture ods.

  • Page 25: Mounting And Assembly

    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...

  • Page 26: Preparation For Installation

    Mounting and assembly 5.2 Preparation for installation Before mounting, make sure the following Mounting position for conditions are met: gases and liquids. − The regulator is clean. − The valve, actuator and all piping are not damaged. − Install a strainer upstream of the regula- tor.
  • Page 27 Mounting and assembly Table 5-1: Inlet and outlet lengths min. min. a x DN b x DN Inlet length Outlet length State of process Valve conditions Inlet length a Outlet length b medium Ma ≤ 0.3 Free of cavitation/w < 3  Liquid Cavitation producing noise/w ≤ 3  EB 2551-1 EN...

  • Page 28: Installation

    Mounting and assembly 5.3 Installation 5.3.2 Cleaning the pipeline The tested SAMSON regulator is delivered We recommend additionally flushing the as an assembled unit. Proceed as follows to pipeline without the installed regulator be- assemble the regulator and before start-up. fore start-up. In this case, install a suitable length of pipe into the pipeline in place of 5.3.1...

  • Page 29: Checking The Regulator

    Flying projectile fragments or the gloves. release of compressed medium 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 30: Leak Test

    The leak test must comply with the The plant operator is responsible for requirements of the national and internation- performing the pressure test. SAMSON's al standards that apply at the site of installa- After-sales Service can support you to plan tion.

  • Page 31: Insulation

    Mounting and assembly 5.5 Insulation To insulate cold systems, we recommend first filling the plant and carefully rinsing it. The regulator must not yet be insulated at this stage. NOTICE Risk of regulator damage due to incorrect insulation. Î Only insulate the regulator up to the ac- tuator for medium temperatures below 0 °C. 1.
  • Page 32 Mounting and assembly EB 2551-1 EN...

  • Page 33: Start-Up

    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 qualified for the dium escaping under pressure. assignment accordingly. Î First start up the regulator after mounting all parts. WARNING Before start-up or putting the valve back into Risk of burn injuries due to hot or cold com- service, make sure the following conditions ponents and pipeline.

  • Page 34: Start-Up And Putting The Regulator Back Into Operation

    Start-up 6.1 Start-up and putting the 6.2 Starting up the plant regulator back into opera- 1. Open the shut-off valves slowly prefera- tion bly starting from the upstream pressure side. Afterwards, open all the valves on 1. Depending on the field of application, the consumer side (downstream of the allow the regulator to cool down or heat regulator).

  • Page 35: Operation

    Operation 7 Operation 7.1 Adjusting the set point Immediately after completing start-up or Î The required downstream pressure is set placing the regulator back into service (see by turning the set point adjuster (9) on the 'Start-up' section), the regulator is ready the pilot valve (8) using an open-end for use.
  • Page 36 Operation EB 2551-1 EN...

  • Page 37: Malfunctions

    8.1 Troubleshooting Malfunction Possible reasons Recommended action Foreign particles blocking the plug in Î Contact SAMSON's After-sales Service. the main valve or pilot valve Downstream pressure exceeds the adjusted Seat and plug in the main valve or Î Contact SAMSON's After-sales Service.

  • Page 38: Emergency Action

    Malfunctions 8.2 Emergency action Note Contact SAMSON's After-sales Service for The plant operator is responsible for emer- malfunctions not listed in the table. gency action to be taken in the plant. We recommend removing the regulator from The malfunctions listed in section 8.1 are the pipeline before repairing it.

  • Page 39: Servicing

    Risk of regulator damage due to the use of become very hot or cold. Risk of burn inju- unsuitable tools. ries. Î Only use tools approved by SAMSON Î Allow components and pipelines to cool (see Annex). down or heat up.

  • Page 40: Preparing The Valve For Service Work

    Î Put the regulator back into operation (see Service. the 'Start-up' section). Make sure the re- − Only use original spare parts by quirements and conditions for start-up or SAMSON, which comply with the original putting the valve back into operation are specifications. met. 9.3 Service work Î...

  • Page 41: Replacing The Seat And Plug

    3. Screw the strainer stopper (13) into the body of the pilot valve. Observe the plug specified tightening torques (see the 'Tightening torques' section in Annex). To replace seat and plug, contact SAMSON's After-sales Service. Further information is available in the An- nex. 9.3.3 Replacing the operating diaphragm To replace the operating diaphragm, contact SAMSON's After-sales Service.

  • Page 42: Ordering Spare Parts And Operating Supplies

    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. Lubricant Contact SAMSON's After-sales Service for more information on lubricants.

  • Page 43: Decommissioning

    Decommissioning 10 Decommissioning WARNING The work described in this section is only to Risk of personal injury due to pressurized be performed by personnel qualified for the components and process medium escaping assignment accordingly. under pressure. Î Do not loosen the control line while the valve is pressurized. DANGER Risk of bursting due to incorrect opening of pressurized equipment or components.
  • Page 44 Decommissioning To decommission the regulator for service work or disassembly, proceed as follows: 1. Close the shut-off valve (1) on the up- stream side of the regulator. 2. Close the shut-off valve (6) on the down- stream side of the regulator. 3.

  • Page 45: Removal

    Removal 11 Removal 11.1 Removing the regulator from the pipeline The work described in this section is only to be performed by personnel qualified for the 1. Support the regulator to hold it in place assignment accordingly. when separated from the pipeline (see the 'Shipment and on-site transport' sec- WARNING tion).
  • Page 46 Removal 11-2 EB 2551-1 EN...

  • Page 47: Repairs

    1. Exceptions apply concerning some spe- Note cial device models u www.samson.de > Service & Support > After-sales Service. Further information on returned devices and how they are handled can be found at u www.samson.de > Service & Support > After-sales Service. EB 2551-1 EN 12-1...
  • Page 48 Repairs 12-2 EB 2551-1 EN...

  • Page 49: Disposal

    Disposal 13 Disposal Î Observe local, national and internation- al refuse regulations. Î Do not dispose of components, lubricants and hazardous substances together with your household waste. EB 2551-1 EN 13-1...
  • Page 50 13-2 EB 2551-1 EN...

  • Page 51: Certificates

    Certificates 14 Certificates The EU declaration of conformity is provided on the next page: − EU declaration of conformity in compli- ance with Pressure Equipment Directive 2014/68/EU on page 14-2. EB 2512 EN 14-1...
  • Page 52 Certificates 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: Sicherheitsabsperrventil SAV 33-1 (2331)/Safety Shut-Off Valve SSV 33-1 (2331) die Konformität mit nachfolgender Anforderung/the conformity with the following requirement.

  • Page 53: Annex

    Set point adjuster (9) Strainer stopper (13) SW 19 Control line connection (10, 11, 12) – 15.2 Lubricant 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.

  • Page 54: Spare Parts

    15.5 Spare parts 15.6 After-sales service There are no spare parts available for the Contact SAMSON's After-sales Service for Type 33-1 Safety Shut-off Valve with Pres- support concerning service or repair work or sure Reducing Valve. when malfunctions or defects arise.
  • Page 56 EB 2551-1 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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