Samson 44-2 Mounting And Operating Instructions
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Samson 44-2 Mounting And Operating Instructions

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EB 2623-1 EN
Translation of original instructions
Type 44-3 Safety Shut-off Valve (SSV) with integrated pressure reducing valve
Red brass body with screwed ends
Type 44-2 Pressure Reducing Valve
Type 44-3 and Type 44-9 Safety Shut-off Valves (SSV) with
integrated pressure reducing valve
Edition January 2024

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Summary of Contents for Samson 44-2

  • Page 1 EB 2623-1 EN Translation of original instructions Type 44-3 Safety Shut-off Valve (SSV) with integrated pressure reducing valve Red brass body with screwed ends Type 44-2 Pressure Reducing Valve Type 44-3 and Type 44-9 Safety Shut-off Valves (SSV) with integrated pressure reducing valve Edition January 2024...
  • 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 ............8 Notes on possible personal injury ..............8 Notes on possible property damage ..............9 Markings on the device ................11 Nameplate ....................11 Location of the nameplate ................11 Material identification number ..............11 Design and principle of operation ..............12 Technical data .....................14 Measures for preparation ................18...
  • Page 4 Contents Preparation for return shipment ..............35 Ordering spare parts and operating supplies ..........35 Malfunctions ....................38 Decommissioning and removal ..............38 10.1 Decommissioning ..................39 10.2 Disposal ......................39 Appendix ....................40 11.1 After-sales service ..................40 11.2 Spare parts ....................40 Certificates ....................43 EB 2623-1 EN...

  • Page 5: Safety Instructions And Measures

    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 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 7 Furthermore, operating personnel must be familiar with the applicable health, safety and accident prevention regulations and comply with them. Safety features The Type 44-2 Regulator does not have any special safety features. The Type 44-3 and Type 44-9 Regulators are safety shut-off valves (SSV) with integrated pressure reducing valve.

  • Page 8: Notes On Possible Severe Personal Injury

    Î Before starting any work on the springs, relieve the compression from the preloaded springs. Î Only use the SAMSON disassembly tool (1280-4052). 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.

  • Page 9: Notes On Possible Property Damage

    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 Parts that are too loose may cause leakage. Î Observe the specified tightening torques. Note SAMSON's After-sales Service can support you concerning lubricant, tightening torques and tools approved by SAMSON. EB 2623-1 EN...

  • Page 11: Markings On The Device

    Markings on the device 2 Markings on the device 2.1 Nameplate 1 Model number 2 Material number and device index 3 Order number or year of manufacture 4 Type designation 5 Pressure rating PN ) coefficient 7 Perm. temperature in °C 8 Set point range in bar 9 Max.

  • Page 12: Design And Principle Of Operation

    (SSV) with integrated rises above the adjusted set point. pressure reducing valve when the down- The Type 44-2, Type 44-3 and Type 44-9 stream pressure rises too far and closes the Pressure Reducing Valves mainly consist of valve. Diaphragm failure is indicated by a...
  • Page 13 Plug nipple Diaphragm stem Seal Screw plug for the Diaphragm plate inspection bore Distance ring Spring plate Valve body Fig. 3: Functional diagram of Type 44-2 Pressure Reducing Valve as well as Type 44-3 and Type 44-9 Safety Shut-off Valves (SSV) EB 2623-1 EN...

  • Page 14: Technical Data

    (SSV) with integrated pressure Table 4 provides a summary of the dimen- reducing valve and are typetested by TÜV. sions and weights of the Type 44-2, Type 44- The test mark is available on request. 3 and Type 44-9 Regulators. The lengths and...
  • Page 15 Design and principle of operation Table 1: Technical data · All pressures in bar (gauge) Regulator Pressure reducing valve 44-2 44-3 (SSV) · 44-9 (SSV) Red brass body Male thread DN 15, 20, 25, 32, 40 and 50 Port Spheroidal graphite iron Flanges DN 32, 40 and 50...
  • Page 16  · 2.5 –  1)  2)  2) Flanged body coefficients Standard version – 12.5 20.0 25.0 Special version of Type 44-2 Special version of Type 44-9 Table 4: Dimensions · Weights Nominal size Length L Pipe Ød 21.3 26.9 33.7 42.4 48.3 60.3 Connection R G ¾...
  • Page 17 Version with welding ends Type 44-2 · Body: CC499K Type 44-3 · Type 44-9 · Body: CC499K R Ød R Ød ØD ØD Version with flanged valve body Type 44-2, Type 44-3 and Type 44-9 Body: spheroidal graphite iron Version with threaded ends  1) Fig. 4: Dimensions DN 32, 40 and 50 EB 2623-1 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 stor- damage. Report any damage to SAM- age conditions or longer storage times. SON and the forwarding agent (refer to delivery note).
  • Page 19 SAMSON's After-sales Service can provide more detailed storage instructions on re- quest. 1 Shut-off valve Type 44-2 Pressure 5 Downstream pressure Reducing Valve gauge 2 Upstream pressure gauge 3 Strainer Fig. 5: Pressure control with Type 44-2 (installation example) EB 2623-1 EN...

  • Page 20: Mounting And Start-Up

    Mounting and start-up 5 Mounting and start-up 5.1 Mounting positions Install Type 44-2, Type 44-3 and Type 44-9 NOTICE NOTICE with the actuator housing suspended down- Risk of overheating due to excessive ambi- ward in horizontal pipelines. ent temperatures or insufficient heat dissi- Installation conditions pation when components are insulated.

  • Page 21: Additional Fittings

    (temperature, carried along by the medium. For example, humidity). the SAMSON Type 1 NI Strainer is suitable − Do not install the device outdoors or in (u T 1010). rooms prone to frost.

  • Page 22: Preparation For Installation

    Mounting and start-up 5.3.1 Cleaning the pipeline Pressure gauges Install a pressure gauge both upstream and We recommend additionally flushing the downstream of the regulator to monitor the pipeline without an installed regulator over a pressures prevailing in the plant (see Fig. 5). time period of several minutes before start- up.

  • Page 23: Installation

    Mounting and start-up 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 chapter is to be Risk of personal injury due to pressurized performed only by personnel appropriately components and as a result of process me- qualified to carry out such tasks. dium being discharged. Î...

  • 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

    (chemical) burns. Wear protective clothing, safety gloves and NOTICE eye protection. Risk of regulator damage due to the use of unsuitable tools. Only use tools approved by SAMSON. EB 2623-1 EN...

  • Page 29: Cleaning And Replacing The Seat And Plug

    The regulator was checked by SAMSON springs. before delivery. − Only use the SAMSON disassembly tool − Certain test results certified by SAMSON (1280-4052). lose their validity when the regulator is opened. Such testing includes seat leakage and leak tests.
  • Page 30 FW 504) for Types 44-3 and 2. Completely relieve the tension from the 44-9 becoming void. set point springs (70…78) by turning the Consult SAMSON's After-sales Service be- set point adjuster (56) counterclockwise fore you change parts or perform service or ().

  • Page 31: Exchanging The Operating Diaphragm

    − Before starting any work on the springs, reface the stem. relieve the compression from the preloaded After replacing the diaphragm stem, the springs. nipple (guide bushing) in the actuator case − Only use the SAMSON disassembly tool must be replaced as well. (1280-4052). EB 2623-1 EN...

  • Page 32: Replacing The Set Point Springs

    (130) evenly. Observe tightening torque set point adjuster (56) counterclockwise specified in Chapter 8.4. (). 6. Use the SAMSON disassembly tool to 3. Remove the device from the pipeline. screw the valve body (30) together with spring plate (95) and the set point 4.
  • Page 33 1. Put the regulator out of operation (see springs. Chapter 10.1). − Only use the SAMSON disassembly tool 2. Completely relieve the tension from the (1280-4052). set point springs (70…78) by turning the set point adjuster (56) counterclockwise ().

  • Page 34: Tightening Torques And Lubricant

    Servicing 8.4 Tightening torques and lubricant Î See Fig. 3 Component Nominal size Tightening torque in Nm Guide nipple (2.6) DN 15 to 25 DN 15 DN 20 DN 25 Coupling nut (4) DN 32 DN 40 DN 50 Plug nipple (27) DN 32 to 50 Screw plug (28) DN 15 to 25 Seat (35) DN 32 to 50 DN 15 to 25...

  • Page 35: Preparation For Return Shipment

    Defective devices can be returned to Contact your nearest SAMSON subsidiary SAMSON for repair. Proceed as follows to or SAMSON's After-sales Service for infor- return devices to SAMSON: mation on spare parts, lubricants and tools. 1. Put the regulator out of operation (see Spare parts Chapter 10.1).
  • Page 36 Servicing 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. Î Draw up an energy balance. Pressure tapped at the wrong Î...
  • Page 37 NOTICE Risk of TÜV approval (based on AGFW worksheet FW 504) for Types 44-3 and 44-9 be- coming void. Consult SAMSON's After-sales Service before you change parts or perform service or repair work on TÜV-tested Type 44-3 and Type 44-9 Regulators. EB 2623-1 EN...

  • Page 38: Malfunctions

    − Wear personal protective equipment. SAMSON's After-sales Service can help during troubleshooting. Further information is available in Chapter 11.1. WARNING We recommend removing the regulator from Risk of personal injury due to residual pro- the pipeline before repairing it.

  • Page 39: Decommissioning

    Decommissioning and removal 10.2 Disposal WARNING Risk of burn injuries due to hot or cold com- ponents and pipeline. We are registered with the German national register for Regulator components and the pipeline may waste electric equipment (stiftung become very hot or cold. Risk of burn inju- ear) as a producer of electrical ries.

  • Page 40: Appendix

    E-mail address You can reach our after-sales service at aftersalesservice@samsongroup.com. Position numbers Addresses of SAMSON AG and its subsid- Plug iaries Restriction assembly The addresses of SAMSON, its subsidiaries, O-ring...
  • Page 41 Appendix DN 15 to 25 70…78 EB 2623-1 EN...
  • Page 42 Appendix DN 32 to 50 70…78 EB 2623-1 EN...

  • Page 43: Certificates

    Certificates 12 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 EB 2623-1 EN...
  • Page 44 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 EB 2623-1 EN...
  • Page 45 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 2623-1 EN...
  • Page 46 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 2623-1 EN...
  • Page 47 Frankfurt am Main, 01. December 2022 Norbert Tollas Peter Scheermesser Senior Vice President Director Global Operations Product Maintenance & Engineered Products Revision 05 Classification: Public · SAMSON AKTIENGESELLSCHAFT · Weismuellerstrasse 3 · 60314 Frankfurt am Main, Germany Seite 1 von 1 EB 2623-1 EN...
  • Page 48 Frankfurt am Main, 01. December 2022 Norbert Tollas Peter Scheermesser Senior Vice President Director Global Operations Product Maintenance & Engineered Products Revision 05 Classification: Public · SAMSON AKTIENGESELLSCHAFT · Weismuellerstrasse 3 · 60314 Frankfurt am Main, Germany Seite 1 von 1 EB 2623-1 EN...
  • Page 49 EB 2623-1 EN...
  • Page 50 EB 2623-1 EN...
  • Page 51 EB 2623-1 EN...
  • Page 52 EB 2623-1 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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44-344-91 n1 ni

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