Samson 41-73 Mounting And Operating Instructions
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Samson 41-73 Mounting And Operating Instructions

Universal excess pressure valve self-operated pressure regulators
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EB 2517 EN
Translation of original instructions
Type 41-73 Universal Excess Pressure Valve
Self-operated Pressure Regulators
Edition January 2021

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Summary of Contents for Samson 41-73

  • Page 1 EB 2517 EN Translation of original instructions Type 41-73 Universal Excess Pressure Valve Self-operated Pressure Regulators Edition January 2021...
  • 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 ..............1-5 Notes on possible property damage .............1-7 Warnings on the regulator ................1-9 Markings on the device ................2-1 Nameplates ....................2-1 Location of the nameplates ................2-2 2.3 Material identification number ..............2-2 2.3.1...
  • Page 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 Lubricant ....................15-1 15.3...

  • Page 5: Safety Instructions And Measures

    Therefore, operators must ensure that the regulators are only used in operating conditions that meet the specifications used for sizing the devices at the ordering stage. 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. Î Refer to the technical data and nameplate for limits and fields of application as well as possible uses.
  • Page 6 Plant operators and operat- ing personnel must observe all hazard statements, warning and caution notes in these mounting and operating instructions. 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 substances database). Î Observe safety measures for handling the device as well as fire prevention and explosion protection measures. Safety features The Type 41-73 Regulator does not have any special safety features. When relieved of pres- sure, the valve is closed by the force of the set point springs. EB 2517 EN...
  • Page 7 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.

  • Page 8: Notes On Possible Severe Personal Injury

    Safety instructions and measures Referenced documentation The following documents apply in addition to these mounting and operating instructions: − Mounting and operating instructions for e.g. Accessories: Compensation chamber u EB 2595 e.g. Type 2 NI Strainer u EB 1015 − Data sheets for Accessories: Compensation chamber · Screw fittings · Control e.g. u T 2595 line connection · Control line Type 2 NI Strainer e.g. u T 1015 −...

  • Page 9: Notes On Possible Personal Injury

    Safety instructions and measures 1.2 Notes on possible personal injury WARNING Crush hazard arising from moving parts. The regulator contains moving parts (set point springs), which can injure hands or fin- gers if inserted into the regulator. Î Do not insert hands or fingers between the set point springs while the regulator is in operation. Î Do not insert hands or fingers between the pillars and set point springs while the regulator is in operation. Î Do not insert hands or fingers between the spring plate and crossbeam while the regulator is in operation. Î...
  • Page 10 WARNING 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 11: Notes On Possible Property Damage

    The lubricants to be used depend on the regulator material. Unsuitable lubricants may corrode and damage surfaces. Î Only use lubricants approved by SAMSON. When in doubt, consult SAMSON. Incorrect control due to the formation of ice on the regulator.
  • Page 12 Î Keep the regulator and the tools used free from solvents and grease. Î Make sure that only suitable lubricants are used. Risk of regulator damage due to incorrectly attached slings. Î Do not attach load-bearing slings to the actuator housing. Note SAMSON's After-sales Service can support you concerning lubricant, tightening torques and tools approved by SAMSON. EB 2517 EN...

  • Page 13: Warnings On The Regulator

    Safety instructions and measures 1.4 Warnings on the regulator Warning Meaning of the warning Location on the device Attention ! Warning to indicate that the set point springs are load- Do not disassemble the There is a risk of serious head or face injury through the valve without sudden release of the set point springs while unscrewing relieving the...
  • Page 14 1-10 EB 2517 EN...

  • Page 15: Markings On The Device

    Markings on the device 2 Markings on the device Several nameplates are affixed to the device. The nameplates are used to identify the sep- arate regulator components (see Fig. 2-1). 2.1 Nameplates Valve nameplate DIN version ANSI version ANSI version · DIN version Valve type Model number with index Set point range or spring range Perm. differential pressure Material number Valve size 10 Perm.

  • Page 16: Location Of The Nameplates

    Markings on the device 2.2 Location of the nameplates 2.3 Material identification number 2.3.1 Type 2417 Valve See the nameplate (11 for DIN/ANSI ver- sion, body material) for the material used. Location of the For more details on the nameplate, see sec- nameplate on the tion 2.1. regulator components 2.3.2 Type 2413 Actuator...

  • Page 17: Design And Principle Of Operation

    Design and principle of operation 3 Design and principle of oper- The valve opens when the upstream pressure rises. ation Î See Fig. 3-1 The Type 41-73 Excess Pressure Valve con- sists of a Type 2417 Opening Valve and a Legend for Fig. 3-1 Type 2413 Actuator. The valve and actuator Valve body (except for tested regulators) are delivered Seat separately and must be assembled together Plug according to these instructions (see the 'In- Balancing bellows stallation' section).
  • Page 18 Design and principle of operation Type 2417 Valve Bellows actuator for DN 15 to 50 12.1 Bellows actuator for DN 65 to 100 Type 2413 Diaphragm Actuator Type 2413 Bellows Actuator for 2 to 6, 5 to 10, 10 to 22 and 20 to 28 bar Fig. 3-1: Functional diagram for regulators, DN 32 to 100 with balancing bellows EB 2517 EN...

  • Page 19: Additional Fittings

    Î See Fig. 3-2 stream and downstream of the regulator to Strainers monitor the pressures prevailing in the plant. We recommend installing a SAMSON Bypass and shut-off valves strainer (2) upstream of the valve. It prevents We recommend installing a shut-off valve (1...

  • Page 20: Technical Data

    Compliance Trims with flow dividers can be used to re- The Type 41-73 Regulator bears both the CE duce noise emission (u T 2517). and EAC marks of conformity. Note The Type 41-73 Regulator is not a safety valve. If necessary, a suitable overpressure Temperature range protection must be installed on site in the Depending on how the regulator is config- plant section. ured, it can be used up to temperatures of 350 °C (see Table 3-1). The minimum tem-...
  • Page 21 Design and principle of operation Table 3-1: Technical data · All pressures in bar (gauge) Valve Type 2417 Valve size DN 15 to 50 DN 65 to 80 DN 100 Pressure rating PN 16, 25 or 40 Max. permissible differential 25 bar 20 bar 16 bar pressure ∆p Valve Max. u T 2500 ∙ Pressure-temperature diagram permissible Metal seal: 350 °C · PTFE soft seal: 220 °C Valve plug temperature EPDM or FKM soft seal: 150 °C · NBR soft seal: 80 °C Leakage class according to Metal seal: leakage class I (≤0.05 % of K coefficient)
  • Page 22 Design and principle of operation Table 3-2: Max. permissible pressure at actuator Set point ranges Max. perm. pressure above the set point adjusted at the actuator 0.05 to 0.25 bar · 0.1 to 0.6 bar 0.6 bar 0.2 to 1.2 bar 1.3 bar 0.8 to 2.5 bar 2.5 bar 2 to 5 bar 5 bar 4.5 to 10 bar · 8 to 16 bar 10 bar 2 to 6 bar · 5 to 10 bar 6.5 bar 10 to 22 bar 8 bar 20 to 28 bar 2 bar Note...
  • Page 23 Bellows – 1.4571 In corrosion-resistant version (CrNi steel) Table 3-5: Dimensions in mm and weights in kg Universal Excess Pressure Valve Type 41-73 Valve size DN 15 DN 20 DN 25 DN 32 DN 40 DN 50 DN 65 DN 80 DN 100 Length L Height H1 Forged steel –...
  • Page 24 Design and principle of operation Table 3-5: Dimensions in mm and weights in kg Universal Excess Pressure Valve Type 41-73 Valve size DN 15 DN 20 DN 25 DN 32 DN 40 DN 50 DN 65 DN 80 DN 100 Standard version with Type 2413 Diaphragm Actuator Height H  3) 0.05 to Actuator ØD = 380 mm, A = 640 cm² 0.25 bar Valve spring force F 1750 N...
  • Page 25 Design and principle of operation Table 3-5: Dimensions in mm and weights in kg Universal Excess Pressure Valve Type 41-73 Valve size DN 15 DN 20 DN 25 DN 32 DN 40 DN 50 DN 65 DN 80 DN 100 Weight for version with Type 2413 Diaphragm Actuator 0.05 to 22.5 23.5 29.5 31.5 0.6 bar Weight, based on 0.2 to...
  • Page 26 Design and principle of operation Dimensional drawings ØD ØD Type 41-73 with diaphragm actuator Type 41-73 with bellows actuator Fig. 3-3: Dimensions 3-10 EB 2517 EN...

  • Page 27: Shipment And On-Site Transport

    Shipment and on-site transport 4 Shipment and on-site trans- 4.2 Removing the packaging port from the regulator The work described in this section is only to The components (valve, actuator and, if ap- be performed by personnel appropriately plicable, control line) of the regulator are de- qualified to carry out such tasks.

  • Page 28: 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 Danger due to suspended loads falling. or turning.

  • Page 29: Lifting The Regulator

    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...

  • Page 30: Storing The Regulator

    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.

  • Page 31: Installation

    Î Make sure the direction of flow matches tion. the direction indicated by the arrow on the body. Pipeline routing Î Contact SAMSON if the mounting posi- The inlet and outlet lengths vary depending tion is not as specified above. on several variables and process conditions and are intended as recommendations. Con-...
  • Page 32 Weld the control line at the side in the mid- dle of the pipe, inclining at a ratio of ap- proximately 1:10 up to the compensation chamber (see Table 5-1 and Fig. 5-2). Control line kit A control line kit for tapping pressure at the valve body is available as an accessory part from SAMSON. EB 2517 EN...
  • Page 33 (16) in addition to the standard with a downward slope. In this case, use a SAMSON screw joint with restriction. “ pipe with screw fittings. EB 2517 EN...

  • Page 34: Preparation For Installation

    Installation 5.2 Preparation for installation Proceed as follows: Î Lay out the necessary material and tools Valve and actuator can be assembled before to have them ready during installation or after the valve has been installed in the work. pipeline. We recommend first installing the Î...
  • Page 35 Installation Table 5-1: Inlet and outlet lengths min. min. a x DN b x DN Control line (e.g. control line kit, see information under ‘Control line’ in section 5.1) Inlet length Outlet length State of process Valve conditions Inlet length a Outlet length b medium Ma ≤ 0.3 Vapors Ma ≤ 0.3...

  • Page 36: Installation

    NOTICE ening torques (see 'Tightening torques' in Risk of regulator damage due to the use of Annex). unsuitable tools. Î Only use tools approved by SAMSON Î Bellows actuator DN 15 to 50 (see 'Tools' in Annex). − Remove the crossbeam (8) from the valve.

  • Page 37: Cleaning The Pipeline

    Installation 5.3.2 Cleaning the pipeline Î Bellows actuator DN 65 to 100 − Remove the crossbeam (8) from the We recommend additionally flushing the valve. pipeline with installed regulator before start- − Unscrew the pillars (8.1). − Screw the pillars (8.1) into the threaded Î Unscrew the control line (17) from the holes (8.3) of the actuator flange as far valve body.

  • Page 38: Testing The Regulator

    Î Do not start up the regulator until all Î Wear protective clothing and safety parts have been mounted. gloves. SAMSON regulators are delivered ready for WARNING use. To test the regulator functioning before Risk of hearing loss or deafness due to loud start-up or putting back the regulator into noise.

  • Page 39: Leak Test

    5.4.2 Pressure test Note The plant operator is responsible for per- forming the pressure test. SAMSON's Af- ter-sales Service can support you to plan and perform a pressure test for your plant. EB 2517 EN...

  • Page 40: Insulation

    Installation 5.5 Insulation 5.5.2 Cold insulation To insulate cold systems, we recommend first 5.5.1 Insulation for medium filling the plant and carefully rinsing it. The temperatures above regulator must not yet be insulated at this stage. 150 °C Only the valve body is to be insulated up to NOTICE the set point springs at the most for medium Risk of regulator damage due to incorrect temperatures above 150 °C.

  • Page 41: 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 qualified to carry out such tasks. discharged. Î Do not loosen the control line while the valve is pressurized.

  • Page 42: Start-Up And Putting The Device Back Into Operation

    Start-up 6.1 Start-up and putting the 6.2.1 Regulation of liquids device back into operation Î To start up the pressure regulator, open shut-off valves slowly. 1. Depending on the field of application, allow the regulator to cool down or Î For liquid medium temperatures above warm up to reach ambient temperature 150 °C, first fill the compensation cham- before start up.

  • Page 43: Operation

    Operation 7 Operation WARNING Immediately after completing start-up or Crush hazard arising from moving parts. placing the regulator back into service (see Î Do not insert hands or fingers between the 'Start-up' section), the regulator is ready the set point springs while the regulator for use.
  • Page 44 Operation An initial adjustment of the set point can also Table 7-1: Set point adjustment · Dimen- be made by changing the spring tension un- sion x til the distance x (see Fig. 7-1 and Table 7-1) Set point is reached. Valve size DN range 8 to 16 bar 15 to 25 32 to 50 65 to 100 10 bar...

  • Page 45: Malfunctions

    Î Contact SAMSON's After-sales Service. Î Remove foreign particles. Foreign particles blocking the plug Î Contact SAMSON's After-sales Service when parts are damaged. Compensation chamber in the wrong Î Reconnect compensation chamber at a different position or too small (with steam).
  • Page 46 Î Contact SAMSON's After-sales Service when Defective bellows seal extension. parts are damaged. Red mark appears at the diaphragm rupture Defective operating diaphragm Î Replace damaged operating diaphragm. indicator (actuator with two diaphragms). Note Contact SAMSON's After-sales Service for malfunctions not listed in the table. EB 2517 EN...

  • Page 47: Emergency Action

    Putting the regulator back into operation after a malfunction See the 'Start-up' section. SAMSON's After-sales Service can support you in drawing up an inspection and test plan for your plant. 8.2 Emergency action Plant operators are responsible for emergen- cy action to be taken in the plant.
  • Page 48 EB 2517 EN...

  • Page 49: Servicing

    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.
  • Page 50 Servicing Note The regulator was checked by SAMSON before it left the factory. − Certain test results certified by SAMSON lose their validity when the regulator is opened. Such testing includes seat leakage Legend for Fig. 9-1 and leak tests. − The product warranty becomes void if...
  • Page 51 Servicing Type 2417 Valve Bellows actuator for DN 15 to 50 12.1 Bellows actuator for DN 65 to 100 Type 2413 Diaphragm Actuator Type 2413 Bellows Actuator for 2 to 6, 5 to 10, 10 to 22 and 20 to 28 bar Fig. 9-1: Functional diagram for regulators, DN 32 to 100 with balancing bellows EB 2517 EN...

  • Page 52: Preparing The Valve For Service Work

    Servicing 9.1 Preparing the valve for 9.3 Service work service work Î Before performing any service work, preparations must be made to the regu- 1. Lay out the necessary material and tools lator (see section 9.1). to have them ready for the service work. Î After all service work is completed, check 2.

  • Page 53: Replacing The Actuator

    Servicing 9.3.1 Replacing the actuator Mounting the actuator 1. Diaphragm actuator DN 15 to 100 Î See Fig. 9-1 Insert the actuator stem (11) through the Removing the actuator hole in the crossbeam onto the spigots of the actuator bellows (5.1). Tighten the 1. Put the regulator out of operation (see nuts (9). Observe the specified tightening the 'Decommissioning' section).

  • Page 54: Replacing The Set Point Springs

    Servicing 9.3.2 Replacing the set point 2. Place the spring plate (7.1), nut (7.2) and needle bearing with axial disk (7.4) springs onto the spigot of the actuator bellows Î See Fig. 9-1 (5.1). 3. DN 15 to 50 without balancing bellows: Removing the set point springs Use an Allen key (4 mm) to hold the bel- 1. Put the regulator out of operation (see lows extension stationary and screw on the 'Decommissioning' section).

  • Page 55: Replacing The Seat And Plug

    3. Unscrew the control line (17). in an FDA-compliant regulator version. 4. Unscrew the nuts (9) and remove the ac- SAMSON's After-sales Service can support tuator. you to perform such service work. 5. Clamp the actuator stem (11) into a suit- able fixture. Mark the side of the actua-...

  • Page 56: Ordering Spare Parts And Operating Supplies

    1. Place a new operating diaphragm (12) onto the diaphragm plate (13) (ensuring Contact your nearest SAMSON subsidiary the pressurized side is facing in the cor- or SAMSON's After-sales Service for infor- rect direction) and tighten the diaphragm mation on spare parts, lubricants and tools. plate nut (14). Observe the specified tightening torques (see 'Tightening Spare parts torques' in Annex).

  • Page 57: 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 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.
  • Page 58 Decommissioning To decommission the regulator for service WARNING WARNING work or disassembly, proceed as follows: Risk of personal injury due to residual 1. Close the shut-off valve (1) on the up- process medium in the regulator. stream side of the regulator. While working on the regulator, residual 2.

  • Page 59: 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 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).
  • Page 60 11-2 EB 2517 EN...

  • Page 61: Repairs

    SAMSON If the regulator does not function properly according to how it was originally sized or Defective devices can be returned to does not function at all, it is defective and SAMSON for repair. Proceed as follows to must be repaired or exchanged. return devices to SAMSON: 1. Put the regulator out of operation (see NOTICE NOTICE the 'Decommissioning' section).
  • Page 62 12-2 EB 2517 EN...

  • Page 63: 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 2517 EN 13-1...
  • Page 64 13-2 EB 2517 EN...

  • Page 65: 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. − EU declaration of conformity in compli- ance with Machinery Directive for Type 41-73 Regulator on page 14-4. − Declaration of incorporation in compli- ance with Machinery Directive 2006/42/EC for the Type 2417 Valve with other actuators other than the Type 2413 Actuator on page . EB 2517 EN...
  • Page 66 Certificates Modul H/Module H, Nr./No. / N° CE-0062-PED-H-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: 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 67 Certificates Modul H/Module H, Nr./No. / N° CE-0062-PED-H-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: Ventile für Druck- Differenzdruck-, Volumenstrom- und Temperaturregler/Valves for pressure, differential pressure, volume flow and temperature regulators 2333 (Erz.-Nr./Model No.
  • Page 68 Certificates 14-4 EB 2517 EN...
  • Page 69 Certificates EB 2517 EN 14-5...
  • Page 70 14-6 EB 2517 EN...

  • Page 71: Annex

    40 to 640 cm² Control line connection (16) – 40 to 640 cm² 15.2 Lubricant 15.4 Accessories SAMSON's After-sales Service can support Table 15-2: Assignment of compensation you concerning lubricants and sealants ap- chamber (18) to regulator, with item no. proved by SAMSON.  ∙  Item number Compensation Type 2413 Actuator...

  • Page 72: Spare Parts

    Annex 15.5 Spare parts Hex nut Crossbeam Washer Version (2012 onwards) Seal Bellows assembly 101, 102 Diaphragm case Coupling nut Screw plug Balancing screw Diaphragm stem Seat Diaphragm plate Plug Diaphragm washer 17.1 Pre-stage of plug Diaphragm 17.2 Seal Hex bolt Body 112 to 114 Hex nut Guide cap Washer Spring Locking pin Guide (DN 32 to 100) 25, 26 Guide bushing/pipe (DN 15 to 25)
  • Page 73 Annex 25/26 Alignment of the point of pressure tapping EB 2517 EN 15-3...

  • Page 74: After-Sales Service

    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 SAMSON product catalogs. Required specifications Please submit the following details: −...
  • Page 78 EB 2517 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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