Samson 2417 Series Service manual

Translation of original instructions
EB 2517 EN
Edition September 2018
Type 41-73 Universal Excess Pressure Valve

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.
ÎFor the safe and proper use of these instructions, read them carefully and keep them for
later reference.
ÎIf you have any questions about these instructions, contact SAMSON‘s After-sales Service
Department (aftersalesser[email protected]).
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.
Denition of signal words
Hazardous situations which, if not avoided,
will result in death or serious injury
Hazardous situations which, if not avoided,
could result in death or serious injury
Property damage message or malfunction
Additional information
Recommended action
DANGER
!
WARNING
!
NOTICE
!
Note
Tip
2 EB 2517 EN

Contents
EB 2517 EN 3
1 Safety instructions and measures ...................................................................5
1.1 Notes on possible severe personal injury .........................................................8
1.2 Notes on possible personal injury ...................................................................9
1.3 Notes on possible property damage..............................................................10
2 Markings on the device ...............................................................................12
2.1 Regulator nameplate ....................................................................................12
2.2 Nameplate position......................................................................................13
2.3 Material number..........................................................................................13
2.3.1 Type 2417 Valve..........................................................................................13
2.3.2 Type2413Actuator .....................................................................................13
3 Design and principle of operation ................................................................14
3.1 Technical data .............................................................................................16
4 Measures for preparation before installation ................................................23
4.1 Unpacking ..................................................................................................23
4.2 Transport, lifting and storage ........................................................................23
4.2.1 Transport.....................................................................................................24
4.2.2 Lifting..........................................................................................................24
4.2.3 Storage.......................................................................................................25
5 Installation..................................................................................................26
5.1 Preparation for installation............................................................................26
5.2 Checking the installation conditions...............................................................27
5.2.1 Mounting position........................................................................................27
5.2.2 Pipeline routing............................................................................................28
5.3 Control line, compensation chamber and needle valve....................................29
5.3.1 Control line .................................................................................................29
5.3.2 Control line kit .............................................................................................29
5.3.3 Compensation chamber................................................................................29
5.3.4 Needle valve ...............................................................................................30
5.4 Additionalttings.........................................................................................30
5.4.1 Strainer.......................................................................................................30
5.4.2 Bypass and shut-off valves ............................................................................31
5.4.3 Insulation ....................................................................................................31
5.4.4 Pressure gauges...........................................................................................31
6 Start-up and operation ................................................................................32
6.1 Start-up.......................................................................................................32
6.1.1 Installing the regulator..................................................................................32
6.1.2 Pipelineushing...........................................................................................33

Contents
4 EB 2517 EN
6.1.3 Pressure test.................................................................................................34
6.2 Starting up the plant.....................................................................................35
6.2.1 Regulation of liquids.....................................................................................35
6.2.2 Regulation of steam......................................................................................35
6.3 Adjusting the set point..................................................................................36
7 Servicing.....................................................................................................37
7.1 Replacing the actuator..................................................................................39
7.2 Replacing the set point springs......................................................................40
7.3 Replacing the seat and plug..........................................................................41
7.4 Replacing the operating diaphragm ..............................................................42
7.5 Tightening torques........................................................................................43
7.6 Lubricants and sealants ................................................................................43
7.7 Accessories .................................................................................................43
7.8 Preparation for return shipment.....................................................................43
7.9 Ordering spare parts and operating supplies .................................................44
8 Malfunctions ...............................................................................................44
9 Decommissioning and removal ....................................................................47
9.1 Decommissioning.........................................................................................47
9.2 Disposal......................................................................................................47
10 Appendix....................................................................................................48
10.1 After-sales service........................................................................................48
10.2 Spare parts .................................................................................................48
10.3 Certicates ..................................................................................................50

EB 2517 EN 5
Safety instructions and measures
1 Safety instructions and measures
Intended use
TheSAMSONType41-73ExcessPressureValveconsistsofaType2417Valveanda
Type2413Actuator.Thevalveandactuatoraredeliveredseparatelyandmustbeassembled
according to the instructions in this document.
The self-operated regulator is used to control the upstream pressure p1in the pipeline to the
adjusted set point. Liquids, gases and vapors in processing and industrial plants can be con-
trolled by the regulator.
Theregulatorsaredesignedtooperateunderexactlydenedconditions(e.g.operating
pressure, process medium, temperature). Therefore, operators must ensure that the regulators
areonlyusedinoperatingconditionsthatmeetthespecicationsusedforsizingthedevices
at the ordering stage. In case operators intend to use the regulators in other applications or
conditionsthanspecied,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.
ÎRefer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denedduringsizingandbythetechnicaldata
–Useoutsidethelimitsdened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
Qualications of operating personnel
The regulator must be mounted, started up, serviced and repaired by fully trained and quali-
edpersonnelonly;theacceptedindustrycodesandpracticesaretobeobserved.Accord-
ing 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appli-
cable standards.

6 EB 2517 EN
Safety instructions and measures
Personal protective equipment
Werecommendcheckingthehazardsposedbytheprocessmediumbeingused(e.g.
uGESTIS(CLP)hazardoussubstancedatabase).
ÎProvide protective equipment (e.g. safety gloves, eye protection) appropriate for the pro-
cess medium used.
ÎWear hearing protection when working near the regulator.
ÎCheck with the plant operator for details on further protective equipment.
Revisions and other modications
Revisions,conversionsorothermodications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
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oper-
ating instructions, especially for installation, start-up and service work.
Wealsorecommendcheckingthehazardsposedbytheprocessmediumbeingused(e.g.
uGESTIS(CLP)hazardoussubstancedatabase).
ÎObservesafetymeasuresforhandlingthedeviceaswellasrepreventionandexplosion
protection measures.
Safety devices
TheType41-73Regulatordoesnothaveanyspecialsafetyequipment.Whenrelievedof
pressure, the valve is closed by the force of the set point springs.
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.

EB 2517 EN 7
Safety instructions and measures
Responsibilities of operating personnel
Operating personnel must read and understand these mounting and operating instructions as
wellasthereferenceddocumentsandobservethespecied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.
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section10.3).
AccordingtotheignitionriskassessmentperformedinaccordancewithEN13463-1:2009,
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 Di-
rective 2014/34/EU.
ÎForconnectiontotheequipotentialbondingsystem,observetherequirementsspeciedin
section6.4ofEN60079-14(VDE0165Part1).
Referenced documentation
The following documents apply in addition to these mounting and operating instructions:
–Mounting and operating instructions for accessories, e.g.
Compensation chamber for Type41-73 Regulators uEB2595
–Data sheet for accessories, e.g.
Accessories
Compensation chamber·Screw ttings·Control line
connection·Control line
uT2595

8 EB 2517 EN
Safety instructions and measures
1.1 Notes on possible severe personal injury
DANGER
!
Risk of bursting in the regulator.
Regulators and pipelines are pressure equipment. Improper opening can lead to com-
ponents bursting.
ÎBeforestartinganyworkontheregulator,depressurizeallplantsectionsconcerned
as well as the valve.
ÎDrain the process medium from all the plant sections concerned as well as the
valve.
ÎWear personal protective equipment.

EB 2517 EN 9
Safety instructions and measures
1.2 Notes on possible personal injury
WARNING
!
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.
ÎDonotinserthandsorngersbetweenthesetpointspringswhiletheregulatorisin
operation.
ÎBeforeperforminganyworkontheregulator,depressurizetheplant.Disconnector
shutofftheexternalcontrolline.
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 indicat-
ed on the SAMSON delivery note.
ÎRead information on safe use of the part affected, see uhttp://www.samson.de/
reach-en.html.
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.
ÎIf possible, drain the process medium from all the plant sections concerned and the
regulator.
ÎWear 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.
ÎAllow components and pipelines to cool down or heat up.
ÎWear protective clothing and safety gloves.

10 EB 2517 EN
Safety instructions and measures
1.3 Notes on possible property damage
NOTICE
!
Risk of regulator damage due to incorrectly attached slings.
ÎDo not attach load-bearing slings to the actuator housing.
Risk of regulator damage due to unsuitable medium properties.
Theregulatorisdesignedforaprocessmediumwithdenedproperties.
ÎOnlyusetheprocessmediumspeciedforsizing.
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.
ÎFlush the pipelines before start-up.
ÎObservethemaximumpermissiblepressureforregulatorandplant.
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.
ÎOnly use lubricants approved by SAMSON. When in doubt, consult SAMSON.
Risk of leakage and regulator damage due to excessively high or low tightening
torques.
Observethespeciedtorquesontighteningregulatorcomponents.Excessivelytightened
torques lead to parts wearing out quicker. Parts that are too loose may cause leakage.
ÎObservethespeciedtighteningtorques.
Risk of regulator damage due to the use of unsuitable tools.
Certain tools are required to work on the regulator.
ÎOnly use tools approved by SAMSON.
SAMSON's After-sales Service department can support you concerning lubricant, tight-
ening torques and tools approved by SAMSON.
Note

EB 2517 EN 11

12 EB 2517 EN
Markings on the device
2 Markings on the device
2.1 Regulator nameplate
1 Valve type
2Modelnumberwithindex
3CongurationID
4 Order number or date
5 KVS coefcient
6 Spring force
7Valvesize
8 Nominal pressure
9 Perm. differential pressure
10 Perm. temperature
11 Body material
SAMSON
DN
Made in Germany
°C
T
bar
∆p
PN
K
vs
No
11
8910
7
6
5
4
1
3
2
Valve nameplate
Actuator nameplate
psi
psi psi
size
cm²
Var.-ID No
SAMSON sq.in
bar bar
DN
Made in Germany
bar
2002
0062
1
3
24
9510 9
6
1 Actuator area (DIN/ANSI)
2 Type
3CongurationID
4 ID number
5Valvesize
(DIN/ANSI)
6
Max.perm.pressure(pexceed) at the actuator,
basedonthemax.adjustablesetpoint(DIN/
ANSI)·SeeTable2
9 Set point range (DIN/ANSI)
10 Diaphragm material
Fig.1: Nameplates

EB 2517 EN 13
Markings on the device
2.3 Material number
2.3.1 Type 2417 Valve
See the nameplate (11, body material). For
more details on the nameplate, see sec-
tion2.1.
2.3.2 Type2413 Actuator
SpecifyingthecongurationID,youcancon-
tactustondoutwhichmaterialisused.The
congurationIDisspeciedonthename-
plate(3,congurationID).Formoredetails
onthenameplate,seesection2.1.
Nameplate
position
Fig.2: Nameplate on the body ange of the Type2417 and on the Type2413 Actuator (diaphragm
or metal bellows)
2.2 Nameplate position
ÎRefertoFig.2.

14 EB 2517 EN
Design and principle of operation
1 Valve body
2 Seat
3 Plug
4 Balancing bellows
5 Plug stem
5.1 Bellows
6 Set point adjuster
7 Set point springs
7.1 Spring plate
7.2 Nut
7.3 Cap screw
7.4 Needlebearingandaxialdisk
8 Crossbeam
8.1 Stud bolt
(view drawn turned by 90°)
8.2 Nuts for stud bolts
8.3 Tapped holes
9 Fastening nuts
10 Diaphragm actuator/bellows actuator
11 Actuator stem
12 Operating diaphragm
12.1 Operating bellows
13 Diaphragm plate
14 Diaphragm plate nut
15 Nuts and bolts
16
ControllineconnectionG¼
(with screw joint with restriction when used
with steam)
17
Control line (to be provided on site)
(available as control line kit for direct
pressure tapping at the body uT2595)
18 Compensation chamber
19 Filler plug
3 Design and principle of oper-
ation
ÎRefertoFig.3
TheType41-73ExcessPressureValvecon-
sistsofaType2417OpeningValveanda
Type2413Actuator.Thevalveandactuator
are delivered separately and must be assem-
bled according to the instructions in sec-
tion6.1.1.
Theexcesspressurevalveisusedtomaintain
the pressure upstream of the valve to an ad-
justed set point.
Theprocessmediumowsthroughthevalve
between seat (2) and plug (3) in the direc-
tion indicated by the arrow on the body. The
position of the valve plug determines the
owrateand,asaresult,thepressureratio
across the valve. The plug stem is sealed by
a frictionless bellows (5.1). The upstream
pressure p1is transmitted over the compen-
sation chamber (18) and control line (17) to
the operating diaphragm (12) (operating
bellows (12.1) in the version with bellows
actuator) where it is converted into a posi-
tioning force. This force is used to move the
valve plug depending on the force of the set
point springs (7). The spring force is adjust-
able at the set point adjuster (6). The valves
with KVS4andhigherhaveabalancingbel-
lows (4). The upstream pressure acts on the
outside of the bellows and the downstream
pressure on the inside of the bellows. As a
result, the forces produced by the upstream
and downstream pressures acting on the
plug are balanced out.
The valve closes when the downstream pres-
sure rises.

EB 2517 EN 15
Design and principle of operation
12.1
16
8.2
10
Bellows actuator
forDN15to50
8.3
10
Bellows actuator
forDN65to100
1
3
2
5
6
4
7
8
9
5.1
11
12
10
18 19
p1p2
17
16
15
8.2
8.1
8.2
7.4
7.1
7.2
7.3
13
14
Type 2417 Valve
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: Functional diagram for regulators, DN32 to 100 with balancing bellows

16 EB 2517 EN
Design and principle of operation
3.1 Technical data
The valve and actuator nameplates provide
information on the valve and actuator ver-
sions(seesection2).
Process medium and scope of application
TheType41-73ExcessPressureValveis
used to maintain the pressure upstream of
the regulator to an adjusted set point.
The regulator is suitable for controlling liq-
uids, gases or vapors up to 350°C.
–For liquids, gases or vapors
–Max.temperature350°C
–Set points from 0.05 to 28bar
–ValvesizeDN15 to 100
–Pressure ratings from PN16 to 40
The regulator is closed when relieved of
pressure. The valve opens when the up-
stream pressure rises.
Temperature range
Dependingonhowtheregulatoriscong-
ured, it can be used up to temperatures of
350°C(Table1).Theminimumtemperature
is limited by the accessories used and the ac-
tuator's diaphram material (uT2595).
Leakage class
The metal-seated regulator has the leakage
classIaccordingtoIEC60534-4.
The soft-seated regulator has the leakage
classIVaccordingtoIEC60534-4.
Noise emission
SAMSON is unable to make general state-
ments about noise emission as it depends on
the regulator version, plant facilities and
process medium.
Risk of hearing loss or deafness due to loud
noise.
Wear hearing protection when working near
the regulator.
The Type41-73 Excess Pressure Valve is not
a safety valve. If necessary, a suitable over-
pressure protection must be installed on site
in the plant section.
Dimensions and weights
Table5providesasummaryofthedimen-
sions and weights. The lengths and heights
in the dimension diagrams are shown on
page22onwards.
WARNING
!
Note

EB 2517 EN 17
Design and principle of operation
Table1: Technical data · All pressures in bar (gauge)
Valve Type2417
Valve size DN 15 20 25 32 40 50 65 80 100
Pressure rating PN16,25or40
Max.permissibledifferential
pressure∆p 25bar 20bar 16bar
Max.perm.
temperature
Valve See pressure-temperature diagram in uT2500
Valve plug Metal seal: 350°C·SoftsealPTFE:220°C
EPDM or FKM soft seal: 150°C · NBR soft seal: 80°C
Leakage class according to
IEC60534-4
Metalseal:leakagerateI(≤0.05%ofKVS)
Softseal:leakagerateIV(≤0.01%ofKVS)
Compliance ·
Diaphragm actuator Type2413
Actuator area cm² 640 320 160 80 40
Set point ranges bar 0.05 to 0.25
0.1 to 0.6 0.2 to 1.2 0.8 to 2.51) 2 to 5 4.5 to 10
8 to 16
Max.perm.temperature
Gases350°C,however,max.80°C at the actuator · Liquids 150°C,
with compensation chamber 350°C · Steam with compensation cham-
ber 350°C
Bellows actuator Type2413
Actuator area cm² 33 62
Set point ranges bar 10to22·20to28 2to6·5to10
1) Versionwithactuatorwithtwodiaphragms:1to2.5bar

18 EB 2517 EN
Design and principle of operation
Table2: Max. permissible pressure at actuator
Set point ranges Max. perm. pressure above the set point adjusted at the
actuator
Diaphragm actuator
0.05to0.25bar 0.6bar
0.1to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 10bar
8to16bar
Bellows actuator
2to6bar 6.5bar
5to10bar
10to22bar 8bar
20to28bar 2bar
Themaximumpermissiblepressureattheactuatordependsonthecurrentlyadjustedset
point. Add the value listed in the table to it.
Example:
Setpointrange:0.2to1.2bar,adjustedsetpoint:0.8bar
Max. permissible pressure atactuator: 0.8bar+1.3bar=2.1bar
Table3: KVS coefcients and xFZ values · Terms for noise level calculation according to
VDMA 24422 (edition 1.89)
Valve size DN 15 20 25 32 40 50 65 80 100
KVS1)·Standardversion 4.0 6.3 8.0 16 20 32 50 80 125
xFZ 0.5 0.45 0.4 0.35
KVS1)·Specialversion 1.0 1.0·4.0 4.0·8.0 322) 80
xFZ 0.6 0.5 0.45 0.4
KVS1)·Withowdivider 3.0 5.0 6.0 12 15 25 38 42 66
1) KVS≤4:valvewithoutbalancingbellows
2) Max.permissible∆p:25bar

EB 2517 EN 19
Design and principle of operation
Table4: Materials · Material numbers according to DIN EN
Valve Type2417
Nominal pressure PN16 PN 25 PN 40
Max.perm.
temperature 300°C 350°C
Body Cast iron Spheroidal graphite
iron Cast steel Stainless steel
EN-GJL-250 EN-GJS-400-18-LT 1.0619 1.4408
Seat CrNi steel CrNiMo steel
Plug Material CrNi steel CrNiMo steel
Seal PTFEwith15%glassber·EPDM·NBR·FKM
Guidebushing CrNi steel
Balancing bellows and
bellows seal Stainless steel 1.4571
Actuator Type2413
Diaphragm actuator Bellows actuator
Diaphragm cases SheetsteelS235JR(St37-2)1) –
Diaphragm EPDM·FKM·NBR·EPDMwithPTFE
protective facing –
Bellows housing – 1.5415/1.4301 (stainless steel only)
Bellows – 1.4571
1) In corrosion-resistant version (CrNi steel)
Table5: Dimensions in mm and weights in kg
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 130 150 160 180 200 230 290 310 350
Height H1 335 390 510 525
Height H2 Forged steel 53 – 70 – 92 98 – 128 –
Other materials 44 72 98 118
1) +10%forallothermaterials
2) Actuatorwithtwodiaphragms:1to2.5bar
3) Actuatorwithtwodiaphragms:HeightH+50mm

20 EB 2517 EN
Design and principle of operation
Table5: Dimensions in mm and weights in kg
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
Set point ranges
0.05 to
0.25bar
Height H3) 445 500 620 635
Actuator ØD=380mm,A=640cm²
Valve spring force F 1750N
0.1 to
0.6bar
Height H3) 445 500 620 635
Actuator ØD=380mm,A=640cm²
Valve spring force F 4400N
0.2 to
1.2bar
Height H3) 430 480 600 620
Actuator ØD=285mm,A=320cm²
Valve spring force F 4400N
0.8 to
2.5bar2)
Height H3) 430 485 605 620
Actuator ØD=225mm,A=160cm²
Valve spring force F 4400N
2to5bar
Height H3) 410 465 585 600
Actuator ØD=170mm,A=80cm²
Valve spring force F 4400N
4.5 to
10bar
Height H3) 410 465 585 600
Actuator ØD=170mm,A=40cm²
Valve spring force F 4400N
8 to
16bar
Height H3) 410 465 585 600
Actuator ØD=170mm,A=40cm²
Valve spring force F 8000N
WeightforversionwithType2413DiaphragmActuator
Set point ranges
0.05 to
0.6bar
Weight, based on
castiron1),approx.
kg
22.5 23.5 29.5 31.5 35 51 58 67
0.2 to
2.5bar 16 18 23.5 25.5 29 45 52 61
2 to
16bar 12 13 18.5 21 24 40 47 56
1) +10%forallothermaterials
2) Actuatorwithtwodiaphragms:1to2.5bar
3) Actuatorwithtwodiaphragms:HeightH+50mm