Samson 44-7, 44-4, 44-8 Mounting And Operating Instructions
EB 2723 EN
Translation of original instructions
Type44-7 Excess Pressure Valve
Red brass body with screwed ends
Type44-7 Excess Pressure Valve
Type44-4 and Type44-8 Safety Excess Pressure Valves (SEV)
Self-operated Pressure Regulators
Edition March 2019
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.
Î For the safe and proper use of these instructions, read them carefully and keep them for
later reference.
Î If you have any questions about these instructions, contact SAMSON‘s After-sales Service
Department (aftersalesservice@samson.de).
The mounting and operating instructions for the devices are included in
the scope of delivery. The latest documentation is available on our website
at www.samson.de > Service & Support > Downloads > Documentation.
Denition of signal words
!
DANGER
Hazardous situations which, if not avoided,
will result in death or serious injury
!
WARNING
Hazardous situations which, if not avoided,
could result in death or serious injury
2 EB 2723 EN
!
NOTICE
Property damage message or malfunction
Note
Additional information
Tip
Recommended action
Contents
1 Safety instructions and measures ...................................................................5
1.1 Notes on possible severe personal injury .........................................................7
1.2 Notes on possible personal injury ...................................................................8
1.3 Notes on possible property damage ................................................................9
2 Markings on the device ...............................................................................10
2.1 Regulator nameplate ....................................................................................10
2.2 Material number ..........................................................................................11
2.3 Warnings ....................................................................................................11
3 Design and principle of operation ................................................................12
3.1 Technical data .............................................................................................14
4 Measures for preparation ............................................................................18
4.1 Unpacking ..................................................................................................18
4.2 Transporting and lifting ................................................................................18
4.3 Storage .......................................................................................................18
4.4 Preparation for installation ............................................................................19
5 Mounting and start-up .................................................................................20
5.1 Mounting positions .......................................................................................20
5.2 Additional ttings .........................................................................................21
5.3 Start-up .......................................................................................................22
5.4 Gases and liquids ........................................................................................22
6 Operation ...................................................................................................22
6.1 Adjusting the set point ..................................................................................22
7 Servicing.....................................................................................................23
7.1 Cleaning and replacing the seat and plug ......................................................24
7.2 Exchanging the operating diaphragm ............................................................26
7.3 Replacing the set point springs ......................................................................28
7.4 Tightening torques and lubricant ...................................................................29
7.5 Preparation for return shipment .....................................................................30
7.6 Ordering spare parts and operating supplies .................................................30
8 Malfunctions ...............................................................................................30
EB 2723 EN 3
Contents
9 Decommissioning and removal ....................................................................33
9.1 Decommissioning .........................................................................................33
9.2 Disposal ......................................................................................................33
10 Appendix ....................................................................................................34
10.1 After-sales service ........................................................................................34
10.2 Spare parts .................................................................................................34
10.3 Certicates ..................................................................................................37
4 EB 2723 EN
Safety instructions and measures
1 Safety instructions and measures
Intended use
The SAMSON Type44-4, Type44-7 and Type44-8 Pressure Regulators are suitable for
pressure control of liquids and gases. The regulators are designed to operate under exactly
dened conditions (e.g. operating pressure, process medium, temperature). Therefore,
operators must ensure that the regulators are only used in operating conditions that meet the
specications used for sizing the devices at the ordering stage. In case operators intend to
use the regulators in other applications or conditions than specied, contact 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.
Î Refer to the technical data and nameplate for limits and elds of application as well as
possible uses.
Reasonably foreseeable misuse
The regulators are not suitable for the following applications:
− Use outside the limits dened during sizing and by the technical data
− Use outside the limits dened by the accessories mounted on the regulator
Furthermore, the following activities do not comply with the intended use:
− Use of non-original spare parts
− Performing service and repair work not described in these instructions
− Changing parts, service or repair work on TÜV-tested Type44-4 and Type44-8
Qualications of operating personnel
The regulator must be mounted, started up, serviced and repaired by fully trained and
qualied personnel only; the accepted industry codes and practices are to be observed.
According to these mounting and operating instructions, trained personnel refers to
individuals who are able to judge the work they are assigned to and recognize possible
hazards due to their specialized training, their knowledge and experience as well as their
knowledge of the applicable standards.
EB 2723 EN 5
Safety instructions and measures
Personal protective equipment
We recommend checking the hazards posed by the process medium being used (e.g.
uGESTIS (CLP) hazardous substance database).
Î Provide protective equipment (e.g. safety gloves, eye protection) appropriate for the pro-
cess medium used.
Î Wear hearing protection when working near the regulator.
Î Check with the plant operator for details on further protective equipment.
Revisions and other modications
Revisions, conversions or other modications 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.
Furthermore, the product may no longer meet the requirements for its intended use.
Warning against residual hazards
To avoid personal injury or property damage, plant operators and operating personnel must
prevent hazards that could be caused in the regulator by the process medium, the operating
pressure, the signal pressure or by moving parts by taking appropriate precautions. They
must observe all hazard statements, warning and caution notes in these mounting and operating instructions, especially for installation, start-up and service work.
We also recommend checking the hazards posed by the process medium being used (e.g.
uGESTIS (CLP) hazardous substance database).
Î Observe safety measures for handling the device as well as re prevention and explosion
protection 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 exposed to any danger.
Responsibilities of operating personnel
Operating personnel must read and understand these mounting and operating instructions as
well as the referenced documents and observe the specied hazard statements, warnings
and caution notes. Furthermore, the operating personnel must be familiar with the applicable
health, safety and accident prevention regulations and comply with them.
6 EB 2723 EN
Safety instructions and measures
Referenced standards and regulations
The regulators comply with the requirements of the European Pressure Equipment Directive
2014/68/EU. Regulators with a CE marking have an EU declaration of conformity, which
includes information about the applied conformity assessment procedure. This EU declaration
of conformity is included in the Appendix of these instructions (see section10.3).
According to the ignition risk assessment performed in accordance with EN13463-1:2009,
section 5.2, the non-electrical regulators do not have their own potential ignition source even
in the rare incident of an operating fault. As a result, they do not fall within the scope of Directive 2014/34/EU.
Î For connection to the equipotential bonding system, observe the requirements specied in
section 6.4 of EN60079-14 (VDE0165 Part 1).
1.1 Notes on possible severe personal injury
!
DANGER
Risk of bursting in pressure equipment.
Regulators and pipelines are pressure equipment. Improper opening can lead to regulator components bursting.
Î Observe the maximum permissible pressure for regulator and plant.
Î If necessary, a suitable overpressure protection must be installed on site in the plant
section.
Î Before starting any work on the regulator, depressurize all plant sections
concerned.
Î Drain the process medium from all the plant sections concerned as well as the reg-
ulator.
Î Wear personal protective equipment.
EB 2723 EN 7
Safety instructions and measures
1.2 Notes on possible personal injury
!
WARNING
Risk of personal injury due to preloaded springs.
Regulators in combination with preloaded set point springs are under tension. These
regulators can be identied by the red warning label on the actuator's set point springs.
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 stems), which can injure hands
or ngers if inserted into the valve.
Î Do not insert hands or ngers between the set point springs while the regulator is in
operation.
Î Before performing any work on the regulator, depressurize the plant. Disconnect or
shut off the external control line.
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. (chemical) burns.
Î If possible, drain the process medium from all the plant sections concerned and the
regulator.
Î Wear protective clothing, safety gloves and eyewear.
Risk of burn injuries due to hot or cold components and pipelines.
Depending on the process medium, regulator components and pipelines may get very
hot or cold and cause burn injuries.
Î Allow components and pipelines to cool down or heat up.
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 indicated on the SAMSON delivery note.
Î Information on safe use of the part affected uwww.samson.de/reach-en.html
8 EB 2723 EN
Safety instructions and measures
1.3 Notes on possible property damage
!
NOTICE
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.
Risk of regulator damage due to unsuitable medium properties.
The regulator is designed for a process medium with dened properties.
Î Only use the process medium specied for sizing.
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 the surface.
Î Only use lubricants approved by SAMSON.
Risk of leakage and regulator damage due to excessively high or low tightening
torques.
Observe the specied torques on tightening regulator components. Excessively tightened
torques lead to parts wearing out quicker. Parts that are too loose may cause leakage.
Î Observe the specied tightening torques.
Risk of regulator damage due to the use of unsuitable tools.
Certain tools are required to work on the regulator.
Î Only use tools approved by SAMSON.
Note
SAMSON's After-sales Service department can support you concerning lubricant, tightening torques and tools approved by SAMSON.
EB 2723 EN 9
Markings on the device
2 Markings on the device
2.1 Regulator nameplate
1 2 3
4 5
6 10 7
8 9
Fig.1: Nameplate
The nameplate of all sizes is afxed to the
body (see Fig.2).
1 Model number
2 Conguration ID (Var.-ID) and device index
3 Order number or year of manufacture
4 Type designation
5 Pressure rating PN
coefcient
6 K
VS
7 Perm. temperature in °C
8 Set point range in bar
9 Max. perm. differential pressure Δp in bar
10 Arrow indicating the direction of ow
Nameplate
position on
the body
Fig.2: Nameplate on the bodies
10 EB 2723 EN
Markings on the device
2.2 Material number
Specifying the conguration ID, you can contact us to nd out which material is used. The
conguration ID is specied on the nameplate (2 (conguration ID and device index).
For more details on the nameplate, see section2.1.
2.3 Warnings
The red adhesive labels indicate hazards
that may arise while working on the regulator. Risk of personal injury.
Î Observe the warnings.
EB 2723 EN 11
Design and principle of operation
3 Design and principle of oper-
ation
Î Refer to Fig.3
The regulator are closed when relieved of
pressure. They open when the upstream
pressure rises above the adjusted set point.
The Type44-4, Type44-7 and Type44-8
Excess Pressure Valves mainly consist of the
valve (1) with seat (2) and plug (3) as well
as the actuator with operating diaphragm
(6.1), set point spring (8) and set point adjuster (10).
The excess pressure valve is used to maintain
the pressure upstream of the regulator to an
adjusted set point.
The process medium ows through the regulator between seat and plug in the direction
indicated by the arrow on the body. The position of the valve plug determines the ow
rate and, as a result, the upstream pressure.
The upstream pressure p
transmitted over the control line (11) to the
operating diaphragm (6.1) where it is converted into a positioning force. This force is
used to move the valve plug according to the
force of the set point spring (8). The spring
force can be adjusted at the set point adjuster (10).
The Type44-8 Safety Excess Pressure Valve
additionally has a second backup diaphragm (6.2). Upon failure of the rst operating diaphragm (6.1) the regulator contin-
ues to function using the backup diaphragm (6.2). In this case, the regulator
functions as a safety valve when the upstream pressure rises too far and opens the
to be controlled is
1
valve. Diaphragm failure is indicated by a
red mark in the diaphragm rupture indicator
(12) (point of response at approx. 1.5bar)
or medium escapes at the test connection.
The Type44-4 Safety Excess Pressure Valve
additionally has a second backup diaphragm (6.2). Upon failure of the rst operating diaphragm (6.1) the regulator is fully
opened. Diaphragm failure is indicated by a
red mark in the diaphragm rupture indicator
(12) (point of response at approx. 1.5bar)
or medium escapes at the test connection.
1 Valve body
1.1 Stopper
1.2 Seal
1.3 Seal
2 Seat
3 Plug with plug seal
3.1 Balancing piston
3.2 Plug nut
3.3 Plug stem
3.4 Plug spring
3.5 Plug nipple
3.6 Guide nipple
4 Coupling nut
5 Inspection bore
6 Actuator housing
6.1 Operating diaphragm
6.2 Backup diaphragm
7 Diaphragm stem
8 Set point spring(s)
9 Spring plate
10 Set point adjuster
11 Control line
12 Diaphragm rupture indicator
13 Body screws
14 Distance ring
15 Diaphragm plate nut
16 Diaphragm plate
17 O-rings
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Design and principle of operation
1.1
3.3
3.4
3.5
3.2
6.2
6.1
3.1
1.2
1.3
3.6
11
12
7
2
p
1.1
6.1
1.2
3.1
3.4
3.6
3.3
4
3
p
1
11
+
Turned into the
plane of
projection
13
7
8
9
10
Type44-8 SEV (DN32 to 50),
DN15 to 25, plug section
body with screwed ends
1
2
p
2
5
15
5
12
14
Type44-4 SEV
16
17
6
1
3
p
2
5
11
+
16
17
1
6
Turned into the
plane of
projection
Type44-8 (DN32 to 50),
anged valve body
Fig.3: Functional diagram of Type44-7 Excess Pressure Valve as well as Types44-4 and 44-8
Safety Excess Pressure Valves (SEV)
EB 2723 EN 13
Design and principle of operation
3.1 Technical data
The regulator's nameplate contains information on the regulator version (see section2.1).
Process medium and scope of application
The excess pressure valve and safety excess
pressure valve are designed to maintain the
pressure upstream of the regulator to the adjusted set point especially in district heating
systems and extended heating systems.
Type44-4, Type44-7 and Type44-8 are
suitable for controlling liquids and gases.
− Max. permissible temperatures for gases
up to 80°C
− Air/nitrogen up to 150°C
− Liquids up to 150°C
The regulator is closed when relieved of
pressure. It opens when the upstream pressure rises above the adjusted set point.
Type test
The Type44-4 and Type44-8 Regulators
have been typetested as safety excess pressure valves (SEV) by the German Technical
Inspectorate (TÜV).
The test mark is available on request.
1)
Temperature range
The Type44-4, Type44-7 and Type44-8
Regulators are designed for a temperature
range from 0 to +150°C.
Leakage class
All regulators have the leakage class I
according to IEC60534-4.
Noise emission
SAMSON is unable to make general statements about noise emission as it depends on
the regulator version, plant facilities, process
medium and operating conditions.
!
WARNING
Risk of hearing loss or deafness due to loud
noise.
Wear hearing protection when working near
the regulator.
Dimensions and weights
Table4 provides a summary of the dimensions and weights of the Type44-4, Type447 and Type44-8 Regulators. The lengths and
heights in the dimensional drawings are
shown on page17 onwards.
1)
With seals made of FKM
14 EB 2723 EN
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