Samson 33-7 Service manual

Translation of original instructions
EB 2551-2 EN
Type33-7 Safety Excess Pressure Valve (SEV)
Self-operated Regulators
Edition July 2020

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.
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
([e-mail]).
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.samsongroup.com > Service & Support > Downloads >
Documentation.
Definition 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
EB 2551-2 EN

Contents
EB 2551-2 EN 1
1 Safety instructions and measures ................................................................1-1
1.1 Notes on possible severe personal injury ......................................................1-4
1.2 Notes on possible personal injury ................................................................1-5
1.3 Notes on possible property damage.............................................................1-7
2 Markings on the device ..............................................................................2-1
2.1 Nameplate .................................................................................................2-1
2.2 Location of the nameplate............................................................................2-1
2.3 Material numbers........................................................................................2-1
3 Design and principle of operation ...............................................................3-1
3.1 Additionalttings........................................................................................3-3
3.2 Technical data ............................................................................................3-4
4 Shipment and on-site transport ...................................................................4-1
4.1 Accepting the delivered goods .....................................................................4-1
4.2 Removing the packaging from the regulator ..................................................4-1
4.3 Transporting and lifting the regulator............................................................4-2
4.3.1 Transporting the regulator............................................................................4-2
4.3.2 Lifting the regulator .....................................................................................4-3
4.4 Storing the regulator ...................................................................................4-4
5 Installation.................................................................................................5-1
5.1 Installation conditions..................................................................................5-1
5.2 Preparation for installation...........................................................................5-3
5.3 Final installation..........................................................................................5-4
5.3.1 Installing the regulator.................................................................................5-4
5.3.2 Cleaning the pipeline ..................................................................................5-4
5.4 Testing the regulator ....................................................................................5-5
5.4.1 Leak test.....................................................................................................5-6
5.4.2 Pressure test................................................................................................5-6
5.5 Insulation ...................................................................................................5-7
6 Start-up .....................................................................................................6-1
6.1 Start-up and putting the device back into operation .......................................6-2
6.2 Starting up the plant....................................................................................6-2
7 Operation..................................................................................................7-1
7.1 Adjusting the set point.................................................................................7-1

Contents
2 EB 2551-2 EN
8 Malfunctions ..............................................................................................8-1
8.1 Troubleshooting ..........................................................................................8-1
8.2 Emergency action .......................................................................................8-2
9 Servicing....................................................................................................9-1
9.1 Preparing the valve for service work.............................................................9-2
9.2 Installing the regulator after service work ......................................................9-2
9.3 Service work...............................................................................................9-2
9.3.1 Cleaningorreplacingthelterinthepilotvalve............................................9-2
9.3.2 Replacing the seat and plug.........................................................................9-4
9.3.3 Replacing the actuator's operating diaphragm ..............................................9-4
9.4 Ordering spare parts and operating supplies ................................................9-4
10 Decommissioning .....................................................................................10-1
11 Removal ..................................................................................................11-1
11.1 Removing the regulator from the pipeline....................................................11-1
12 Repairs ....................................................................................................12-1
12.1 Returning devices to SAMSON ..................................................................12-1
13 Disposal...................................................................................................13-1
14 Certicates...............................................................................................14-1
15 Annex......................................................................................................15-1
15.1 Tightening torques.....................................................................................15-1
15.2 Lubricant..................................................................................................15-1
15.3 Tools ........................................................................................................15-1
15.4 Accessories ..............................................................................................15-1
15.5 Spare parts ..............................................................................................15-2
15.6 After-sales service.....................................................................................15-2

EB 2551-2 EN 1-1
Safety instructions and measures
1 Safety instructions and measures
Intended use
TheSAMSONType33-7Regulatorisasafetyexcesspressurevalve(SEV).
The self-operated regulator is used to control the upstream pressure p1in the pipeline to the
adjusted set point. Liquids and gases in processing and industrial plants can be controlled by
the regulator.
Theregulatorisdesignedtooperateunderexactlydenedconditions(e.g.operating
pressure, process medium, temperature). Therefore, operators must ensure that the regulator
isonlyusedinoperatingconditionsthatmeetthespecicationsusedforsizingtheregulator
at the ordering stage. In case operators intend to use the regulator 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 regulator is 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additionalttings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
− ModicationofpartsaswellasserviceorrepairworkonTÜV-testedtheType33-7
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must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.

1-2 EB 2551-2 EN
Safety instructions and measures
Safety features
TheType33-7Regulatorisasafetyexcesspressurevalve(SEV).Whenrelievedofpressure,
the regulator is closed by the force of the positioning springs.
Personal protective equipment
Werecommendcheckingthehazardsposedbytheprocessmediumbeingused(e.g.
uGESTIS(CLP)hazardoussubstancesdatabase).Dependingontheprocessmediumand/
or the activity, the protective equipment required includes:
− Protectiveclothing,safetyglovesandeyeprotectioninapplicationswithhot,coldand/or
corrosive media
− Wearhearingprotectionwhenworkingnearthevalve
− Hard hat
− Safety harness when working at height
− Safetyfootwear,ESD(electrostaticdischarge)footwear,ifnecessary
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.
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 or by moving parts by taking appropriate precautions. 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identied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).
ÎObservesafetymeasuresforhandlingthedeviceaswellasrepreventionandexplosion
protection measures.

EB 2551-2 EN 1-3
Safety instructions and measures
Responsibilities of the operator
Operators are 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,operatorsmustensurethatoperatingpersonnelorthirdparties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speciedhazardstatements,warnings
and caution notes. Furthermore, operating personnel must be familiar with the applicable
health, safety and accident prevention regulations and comply with them.
Theoperatorisadditionallyresponsibleforensuringthatthelimitsfortheproductdenedin
the technical data are observed. This also applies to the start-up and shutdown procedures.
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.
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'Certicates'section.
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
Directive2014/34/EU.
ÎForconnectiontotheequipotentialbondingsystem,observetherequirementsspeciedin
section6.4ofEN60079-14(VDE0165-1).

1-4 EB 2551-2 EN
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.
ÎObservethemaximumpermissiblepressureforregulatorandplant.
ÎBeforestartinganyworkontheregulator,depressurizeallplantsectionsaffected
as well as the regulator.
ÎDraintheprocessmediumfromalltheplantsectionsaffectedaswellasthe
regulator.
ÎWearpersonalprotectiveequipment.
Referenced documentation
The following documents apply in addition to these mounting and operating instructions:
− Mounting and operating instructions for
e.g. Type2N/NI Strainer uEB1015
− Datasheetsfor
e.g. Type2N/NI Strainer uT1015
− Mountingandoperatinginstructionsaswellasdatasheetsforadditionalttings
(e.g. shut-off valves, pressure gauges etc.).

EB 2551-2 EN 1-5
Safety instructions and measures
1.2 Notes on possible personal injury
WARNING
!
Risk of personal injury through incorrect operation, use or installation as a result of
information on the regulator being illegible.
Over time, markings, labels and nameplates on the regulator may become covered
withdirtorbecomeillegibleinsomeotherway.Asaresult,hazardsmaygounno-
ticed and the necessary instructions not followed. There is a risk of personal injury.
ÎKeep all relevant markings and inscriptions on the device in a constantly legible
state.
ÎImmediately renew damaged, missing or incorrect nameplates or labels.
Risk of hearing loss or deafness due to loud noise.
The noise emissions depend on the valve version, plant facilities and process medium.
ÎWearhearingprotectionwhenworkingnearthevalve.
Risk of personal injury due to pressurized components and process medium being
discharged.
Incorrect opening of pressure equipment or mounting parts may lead to the process
medium escaping to the atmosphere.
ÎDonotloosenthecontrollinewhilethevalveispressurized.
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 warm up to the ambient tempera-
ture.
ÎWearprotectiveclothingandsafetygloves.

1-6 EB 2551-2 EN
Safety instructions and measures
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.
ÎInformation on safe use of the part affected uwww.samsongroup.com/en/
about-samson/material-compliance/reach-regulation/
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 affected and the
regulator.
ÎWearprotectiveclothing,safetyglovesandeyeprotection.

EB 2551-2 EN 1-7
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.
SAMSON's After-sales Service can support you concerning lubricant, tightening torques
and tools approved by SAMSON.
Note

1-8 EB 2551-2 EN

EB 2551-2 EN 2-1
Markings on the device
2 Markings on the device
2.1 Nameplate
21347
9111310 128
Var.-IDK
VS m³/h
PN DN
bar
°C
56
14
DIN/ANSI version
1 Type
2 Pressure rating in PN
3 Material number
4ValvesizeinDN
5 Perm. temperature in °C
6 KVScoefcient
7 Body material
8TÜVregistrationnumber
9 p1or p2
10 Set point range
11 Order number
12 SAP number
13 QR code
14 Dateofmanufacture
Fig.2-1: Regulator nameplate
2.2 Location of the nameplate
Location of the
nameplate
Fig.2-2: Nameplate of Type33-7 Regulator
2.3 Material numbers
The material designation can be found on
the nameplate (7, body material) or you can
contactus(thecongurationIDspecication
isneeded)tondoutwhichmaterialisused.
Thisisspeciedonthenameplateinthe
'MNo'eld(3).Formoredetailsonthe
nameplate,seesection2.1.

2-2 EB 2551-2 EN

EB 2551-2 EN 3-1
Design and principle of operation
3 Design and principle of oper-
ation
ÎSeeFig.3-1
TheType33-7ExcessPressureValve(SEV)
consists of the main valve with actuator and
the pilot valve attached to it.
Thesafetyexcesspressurevalveisusedto
maintain the pressure upstream of the main
valve to a set point adjusted at the pilot
valve.
Thesafetyexcesspressurevalveopensasthe
upstream pressure p1rises.
Whenthesafetyexcesspressurevalvestarts
toopen,theprocessmediumrstows
through the pilot valve (8) before the main
valve(1)opens.Duringwhich,theforces
acting on the plug in the main valve are
eliminated by the balancing bellows (5).
The upstream pressure p1is fed through the
control line (10) to the pilot valve (8). The
pilot valve (8) creates a control pressure pS. It
functionsasanexcesspressurevalveand
controls the main valve (1).
The control pressure pSis transferred through
the control line (12) and acts on the operat-
ing diaphragm (6).
The control pressure pSdrops when the
upstream pressure p1rises. The force
resulting from the control pressure pSacting
on the operating diaphragm (6) and the
forces created at the positioning springs (7)
fall below the force of the prevailing
upstream pressure p1. The main valve (1)
opens.
A decrease in upstream pressure p1causes
the control pressure pSto rise. As a result,
the control pressure pSgradually reaches the
same level of the upstream pressure p1
causing the main valve (1) to be closed by
the positioning springs (7).
Upon failure of the operating diaphragm (6),
thesafetyexcesspressurevalveopensand
the pressure falls below the adjusted pres-
sure p1.
To ensure proper functioning of the regulator,
the minimum differential pressure Δpmin must
correspond to the pressure specied in Table
3-1.
Note

3-2 EB 2551-2 EN
Design and principle of operation
10
10.1
1
2
3
11
6
7
p1
p2
p1
pS
p1
p2
pS
12
4
58
8.1
8.2
9
1Main valve
2Seat
3Plug
4Plug stem
5Balancing bellows
6Operating diaphragm
7Positioning springs
8Pilot valve
8.1 Filter
8.2 Set point springs
9Set point adjuster
10 Control line for upstream pressure p1
10.1 Control line for upstream pressure p1
11 Control line for downstream pressure p2
12 Control line for control pressure (pS)
Fig.3-1: Functional diagram of Type33-7

EB 2551-2 EN 3-3
Design and principle of operation
3.1 Additional ttings
ÎSeeFig.3-2
Strainers
WerecommendinstallingaSAMSON
strainer (2) upstream of the valve. It prevents
solid particles in the process medium from
damaging the regulator.
ÎDonotusethestrainertopermanently
ltertheprocessmedium.
ÎSelectastrainer(meshsize)suitablefor
the process medium.
Pressure gauges
Install a pressure gauge at a suitable point to
monitor the pressures prevailing in the plant
(3 and 5).
Any impurities carried along by the process
medium may impair the proper functioning
of the regulator. We recommend installing a
strainer (e.g. SAMSON Type2NI) upstream
of the excess pressure valve (uEB1015).
Shut-off valves
Werecommendinstallingashut-offvalve(1
and 6) both upstream of the strainer and
downstream of the regulator. The shut-off
valves ensure that the entire plant does not
need to be shut down for service and repair
work on the regulator.
Insulation
Regulators can be insulated to reduce heat
energy transfer.
Refer to the instructions in the 'Installation'
section.
Note
1 42 5 63
-
1Shut-off valve
2Strainer
3Upstream pressure gauge
4Safetyexcesspressurevalve(SEV)
5Downstreampressuregauge
6Shut-off valve
Fig.3-2: Sample application

3-4 EB 2551-2 EN
Design and principle of operation
3.2 Technical data
The regulator nameplate provides informa-
tion on the regulator version (see the 'Mark-
ings on the device' section).
More information is available in Data Sheet
uT2551.
Conformity
TheType33-7RegulatorbearsboththeCE
and EAC marks of conformity.
Process medium and scope of application
The Type33-7SafetyExcessPressureValve
(SEV)isusedtomaintainthepressureup-
stream of the regulator to an adjusted set
point.
− Suitable for gases and liquids
− Max.temperature150°C
− Set points from 1 to 11bar
− Flow rate set point from
0.05 to 520m³/h
− ValvesizeDN65 to 250
− Pressure ratings from PN16 to 40
The regulator is closed when relieved of
pressure. The valve opens when the up-
stream pressure rises.
Leakage class
The soft-seated regulator has the leakage
classIVaccordingtoIEC60534-4.
Note
Type test
The device has been typetested as a safety
excesspressurevalve(SEV)bytheGerman
TechnicalInspectorate(TÜV)accordingtothe
requirementsstipulatedintheAGFW(Ger-
manDistrictHeatingAssociation)document
FW504(seeTable3-1).
The test mark is available on request.
Temperature range
Dependingonhowtheregulatoriscong-
ured and the process medium used, it can be
useduptotemperaturesof150°C(seeTa-
ble 3-1). The minimum temperature is limited
by the accessories used and the actuator's
diaphragm material (uT2551).
Noise emissions
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.
Dimensions and weights
Table 3-4 provides a summary of the dimen-
sions and weights. The lengths and heights
in the dimensional drawing are shown on
page3-7.

EB 2551-2 EN 3-5
Design and principle of operation
Table 3-1: Technical data · All pressures in bar (gauge)
Valve size DN 65 80 100 125 150 2002) 2502)
Pressure rating PN16,25or40
Max.permissibletemperature 150°C1)
Set point range (continuously
adjustable) 1to11bar
Minimumdiff.pressure∆pmin 0.4bar 0.5bar 0.6bar
Max.perm.differentialpressure∆p 16bar 12bar 10bar
Max.perm.upstreampressurep116bar
Conformity ·
1) Valvebodymadeofcastiron(EN-GJL-250),DN125to250:max.130°C,takingintoaccountthe
materialtableinDIN4747-1fortheuseoftheregulatorinhot-waterdistrictheatingnetworks.
2) DN200and250aswellassetpointrange1to16bar(nottypetested)availableonrequest.Itis
notpossibletotypetestvalvesinDN200and250sincethetestspecicationonlyappliesto
KVS380atthemaximum.However,theirdesignandfunctionareidenticaltothoseofthetypetest-
edvalvesizes.
Table 3-2: KVS coefcients and xFZ values · Terms for noise level calculation according to
VDMA 24422 (edition 1.89)
Valve size DN 65 80 100 125 150 200 250
KVScoefcient 50 80 125 190 280 420 500
ValueatKVS 0.31) 1.6 1.7 2.0 2.4 3.0 5.0
xFZ value 0.40 0.35 0.30
1) 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speciedvalueatKVS0.3duetothecloggingupof
thevalve.Thisvalueisthensignicantonsizingthesafetyvalveorsafetyexcesspressurevalvein
the plant.

3-6 EB 2551-2 EN
Design and principle of operation
Table 3-3: Materials · Material number according to DINEN
Valve
Pressure rating PN16 PN16·PN25 PN16·PN25·PN40
Body Cast iron
EN-GJL-250
Spheroidal graphite iron
EN-GJS-400-18-LT1)
Cast steel
1.0619
Seat Stainless steel 1.4006
Plug with
EPDMseal
DN65to100 Stainless steel 1.4006
DN125to250 Stainless steel 1.4301
Balancing bellows Stainless steel 1.4571
Seal Graphiteonmetalcore
Actuator
Diaphragmcases SheetsteelDD11(StW22)
Diaphragm EPDMwithfabricreinforcement
Guidebushing DUbushingwithEPDMseal
Pilot valve
Body BrassCW600N/1.4541
Plug BrassCW617N
Metal bellows BrassCW502L
Control lines Steel, special version: copper
Screwttings Steel
1) DN150andsmaller
Table 3-4: Dimensions in mm and weights in kg
Valve size DN65 DN80 DN100 DN125 DN150 DN200 DN250
Length L 290 310 350 400 480 600 730
Height H1) 335 390 510
Height H2 100 120 145 175 235 260
Actuator area A=640cm²
Diaphragmhousing ØD=380mm
Weight(approx.)forPN162) 53kg 58kg 66kg 96kg 140kg 280kg 330kg
1) +15mmforPN40
2) +10%forcaststeel1.0619andspheroidalgraphiteironEN-GJS-400-18-LT