Samson 41-73 Series Service manual

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

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 2517 EN

Contents
EB 2517 EN
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
1.4 Warnings on the regulator...........................................................................1-9
2 Markings on the device ..............................................................................2-1
2.1 Nameplates................................................................................................2-1
2.2 Location of the nameplates ..........................................................................2-2
2.3 Materialidenticationnumber .....................................................................2-2
2.3.1 Type 2417 Valve.........................................................................................2-2
2.3.2 Type2413Actuator ....................................................................................2-2
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...........................................................................5-4
5.3 Installation..................................................................................................5-6
5.3.1 Installing the regulator.................................................................................5-6
5.3.2 Cleaning the pipeline ..................................................................................5-7
5.4 Testing the regulator ....................................................................................5-8
5.4.1 Leak test.....................................................................................................5-9
5.4.2 Pressure test................................................................................................5-9
5.5 Insulation .................................................................................................5-10
5.5.1 Insulationformediumtemperaturesabove150°C.......................................5-10
5.5.2 Cold insulation..........................................................................................5-10

Contents
EB 2517 EN
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
6.2.1 Regulation of liquids....................................................................................6-2
6.2.2 Regulation of steam.....................................................................................6-2
7 Operation..................................................................................................7-1
7.1 Adjusting the set point.................................................................................7-1
8 Malfunctions ..............................................................................................8-1
8.1 Troubleshooting ..........................................................................................8-1
8.2 Emergency action .......................................................................................8-3
9 Servicing....................................................................................................9-1
9.1 Preparing the valve for service work.............................................................9-4
9.2 Installing the regulator after service work ......................................................9-4
9.3 Service work...............................................................................................9-4
9.3.1 Replacing the actuator.................................................................................9-5
9.3.2 Replacing the set point springs.....................................................................9-6
9.3.3 Replacing the seat and plug.........................................................................9-7
9.3.4 Replacing the operating diaphragm .............................................................9-7
9.4 Ordering spare parts and operating supplies ................................................9-8
10 Decommissioning .....................................................................................10-1
11 Removal ..................................................................................................11-1
11.1 Removing the regulator from the pipeline....................................................11-1
11.2 Removing the actuator from the valve .........................................................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.....................................................................................15-4

EB 2517 EN 1-1
Safety instructions and measures
1 Safety instructions and measures
Intended use
TheSAMSONType41-73Regulatorisanexcesspressurevalve.It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pres-
sure, 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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
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 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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.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 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.
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 1-3
Safety instructions and measures
Responsibilities of the operator
Operators are responsible for proper use and compliance with the safety regulations. Opera-
tors are obliged to provide these mounting and operating instructions as well as the refer-
enced documents to the operating personnel and to instruct them in proper operation. Fur-
thermore,operatorsmustensurethatoperatingpersonnelorthirdpartiesarenotexposedto
any danger.
Operatorsare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.
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.
Referenced standards, directives 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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0165-1).

1-4 EB 2517 EN
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
e.g. Accessories:Compensationchamber·Screwttings·Control
lineconnection·Controlline uT2595
e.g. Type2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.).
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regula-
tor.

EB 2517 EN 1-5
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n-
gers if inserted into the regulator.
ÎDonotinserthandsorngersbetweenthesetpointspringswhiletheregulatoris
in operation.
ÎDonotinserthandsorngersbetweenthepillarsandsetpointspringswhilethe
regulator is in operation.
ÎDonotinserthandsorngersbetweenthespringplateandcrossbeamwhilethe
regulator is in operation.
ÎBeforeperforminganyworkontheregulator,depressurizetheplant.Disconnector
shut off the control line.
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 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.

1-6 EB 2517 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 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.
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 loaded springs.
The set point springs of regulators with adjusted set point are preloaded and are under
tension.
ÎBeforestartinganyworkonthesprings,relievethecompressionfromthepreload-
ed springs.

EB 2517 EN 1-7
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.
ÎFlush the pipelines before start-up.
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 surfaces.
ÎOnly use lubricants approved by SAMSON.
When in doubt, consult SAMSON.
Incorrect control due to the formation of ice on the regulator.
Mediumtemperaturesbelow0°Cmaycauseicetoformontheregulator,depending
on the air humidity. This may affect, in particular, the functioning of the plug or dia-
phragm stem guide.
ÎPrevent the formation of ice by taking appropriate precautions (e.g. enclosure,
trace heater etc.). The plant operator is responsible for selecting and implementing
appropriate precautions. See the 'Installation' section.
Risk of excess pressure damaging plant sections due to construction-related seat
leakage through the regulator.
ÎAlwaysinstallasafetydevice(e.g.safetyexcesspressurevalveorsafetyrelief
valve) in the plant.
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.

1-8 EB 2517 EN
Safety instructions and measures
Riskofleakageandregulatordamageduetoexcessivelyhighorlowtightening
torques.
Observethespeciedtorqueswhentighteningregulatorcomponents.Excessivetight-
ening torques lead to parts wearing out more quickly. Parts that are too loose may
cause leakage.
ÎObservethespeciedtighteningtorques(see'Tighteningtorques'inAnnex).
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.
When in doubt, consult SAMSON.
Risk of the process medium being contaminated through the use of unsuitable lubri-
cants and/or contaminated tools and components.
ÎKeep the regulator and the tools used free from solvents and grease.
ÎMake sure that only suitable lubricants are used.
Risk of regulator damage due to incorrectly attached slings.
ÎDonotattachload-bearingslingstotheactuatorhousing.
SAMSON's After-sales Service can support you concerning lubricant, tightening torques
and tools approved by SAMSON.
Note

EB 2517 EN 1-9
Safety instructions and measures
1.4 Warnings on the regulator
Warning Meaningofthewarning Location on the device
Attention !
Donot
disassemble the
valve without
relieving the
tension from the
set point spring.
Warning to indicate that the set point springs are load-
ed.
There is a risk of serious head or face injury through the
sudden release of the set point springs while unscrewing
the crossbeam when the set point springs are loaded.
Completely relieve
the tension from
the set point
springs before
unthreading the
two nuts.
Warning to indicate that the set point springs are load-
ed.
Thereisariskofinjurytohandsorngersthroughthe
sudden release of the actuator stem if they are inserted
betweenthecrossbeamandsetpointspringswhileex-
changing the actuator.
Unlock/unlockthe
plug stem
Warningtoindicatepropertydamageatthebellows
seal.
There is a risk of damage to the bellows seal due to the
incorrect mounting or removal of the plug stem.

1-10 EB 2517 EN

EB 2517 EN 2-1
Markings on the device
2 Markings on the device
Severalnameplatesareafxed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
2314 5
11109876
2314 5
11109876
ANSIversion·DINversion
1 Valve type
2Modelnumberwithindex
3 Material number
4 Order number or date
5 KVS/CV
6 Set point range or spring range
7Valvesize
8 Pressure rating
9 Perm. differential pressure
10 Perm. temperature
11 Bodymaterial
Actuator nameplate
DIN/ANSI version
1Actuatorarea(DIN/ANSI)
2 Actuator model
2.1 Valve model
3 Material number
4IDnumber
5YearwhentheCEcerticationwasissued
6.2 Max.perm.pressureattheactuator,basedon
themax.adjustablesetpoint(DIN/ANSI)
7Valvesize(DIN/ANSI)
9Setpointrange(DIN/ANSI)
10 Diaphragmmaterial
11 CE marking
12 Certicationbodynumber
DIN/ANSIversion
6.2
22.1 34 1115
97 910 12
Fig.2-1: Nameplates of regulator parts

2-2 EB 2517 EN
Markings on the device
2.2 Location of the nameplates
Location of the
nameplate on the
regulator
components
Fig.2-2: Nameplate of the Type2417 Valve
and on the Type2413 Actuator
(diaphragm or bellows)
2.3 Materialidentication
number
2.3.1 Type 2417 Valve
Seethenameplate(11forDIN/ANSIver-
sion, body material) for the material used.
For more details on the nameplate, see sec-
tion2.1.
2.3.2 Type2413Actuator
Specifying the material number, you can
contactustondoutwhichmaterialisused.
Thisisspeciedonthenameplateinthe
'Mat.-No.'eld(3forDIN/ANSI).Formore
detailsonthenameplate,seesection2.1.

EB 2517 EN 3-1
Design and principle of operation
3 Design and principle of oper-
ation
ÎSeeFig.3-1
TheType41-73ExcessPressureValvecon-
sistsofaType2417OpeningValveanda
Type2413Actuator.Thevalveandactuator
(exceptfortestedregulators)aredelivered
separately and must be assembled together
according to these instructions (see the 'In-
stallation' section).
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 opens when the upstream pressure
rises.
LegendforFig.3-1
1Valve body
2Seat
3Plug
4Balancingbellows
5Plug stem
5.1 Bellows
6Set point adjuster
7Set point springs
7.1 Spring plate
7.2 Nut
7.3 Cap screw
7.4 Needlebearingandaxialdisk
8Crossbeam
8.1 Pillar
(viewdrawnturnedby90°)
8.2 Nuts for pillars
8.3 Tapped holes
9Fastening 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

3-2 EB 2517 EN
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.3-1: Functional diagram for regulators, DN32 to 100 with balancing bellows

EB 2517 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.
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).
Note
Pressure gauges
Install a pressure gauge (3 and 5) both up-
stream and downstream of the regulator to
monitor the pressures prevailing in the plant.
Bypass and shut-off valves
We recommend installing a shut-off valve (1
and 6) both upstream of the strainer and
downstream of the regulator and installing a
bypass line. The bypass ensures that the
plant does not need to be shut down for ser-
vice and repair work on the regulator.
Insulation
Regulators can be insulated to reduce heat
energy transfer.
Refer to the instructions in the 'Installation'
section.
1 Shut-off valve
2 Strainer
3 Upstream pressure gauge
4Excesspressurevalve
5Downstreampressuregauge
6 Shut-off valve
18 Compensation chamber, e.g. for
steam
12 435618
Fig.3-2: Installation example

3-4 EB 2517 EN
Design and principle of operation
Noise emissions
Trimswithowdividerscanbeusedtore-
duce noise emission (uT2517).
The Type41-73 Regulator is not a safety
valve. If necessary, a suitable overpressure
protection must be installed on site in the
plant section.
3.2 Technical data
The valve and actuator nameplates provide
information on the valve and actuator ver-
sions (see the 'Markings on the device' sec-
tion).
More information is available in Data Sheet
uT2517.
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.
−For liquids, gases and 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.
Note
Note
Compliance
TheType41-73RegulatorbearsboththeCE
and EAC marks of conformity.
Temperature range
Dependingonhowtheregulatoriscong-
ured, it can be used up to temperatures of
350°C(seeTable3-1).Theminimumtem-
perature is limited by the accessories used
and the actuator's diaphragm 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 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 3-5 provides a summary of the dimen-
sions and weights. The lengths and heights
in the dimensional drawings are shown on
page3-10.