Samson 41-73 Series Service manual

Mounting and
Operating Instructions
EB 2517 EN
Edition July 2015
Self-operated Pressure Regulators
Type41-73 Universal Excess Pressure Valve
Type 41-73 Excess Pressure Valve

Denition of signal words
DANGER!
Hazardous situations which, if not
avoided, will result in death or seri-
ous injury
WARNING!
Hazardous situations which, if not
avoided, could result in death or seri-
ous injury
NOTICE
Property damage message or mal-
function
Note:
Additional information
Tip:
Recommended action

2 EB 2517 EN

Contents
EB 2517 EN 3
1 General safety instructions .............................................................................4
2 Process medium and scope of application .......................................................5
2.1 Transportation and storage.............................................................................5
3 Design and principle of operation ..................................................................5
4 Installation ....................................................................................................6
4.1 Assembly ......................................................................................................6
4.2 Mounting position..........................................................................................8
4.3 Control line, compensation chamber and needle valve......................................9
4.4 Strainer(lter)..............................................................................................10
4.5 Shut-off valve...............................................................................................11
4.6 Pressure gauge ............................................................................................11
5 Operation ...................................................................................................12
5.1 Start-up.......................................................................................................12
5.2 Adjusting the set point..................................................................................12
5.3 Decommissioning.........................................................................................13
6 Cleaning and maintenance ..........................................................................14
6.1 Replacing the operating diaphragm ..............................................................14
7 Nameplate ..................................................................................................16
8 Dimensions .................................................................................................17
9 Customer inquiries ......................................................................................18
10 Technical data .............................................................................................19

4 EB 2517 EN
General safety instructions
1 General safety instructions
−The regulator is to be mounted, started up or serviced by fully trained and
qualiedpersonnelonly;theacceptedindustrycodesandpracticesareto
be observed. Make sure employees or third persons are not exposed to any
danger.
−All safety instructions and warnings given in these mounting and operating
instructions, particularly those concerning installation, start-up and mainte-
nance, must be strictly 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 dangers due to their specialized training, their
knowledge and experience as well as their knowledge of the applicable
standards.
−The regulators comply with the requirements of the European Pressure Equip-
ment Directive 2014/68/EU. Devices with a CE marking have a declaration
of conformity, which includes information about the applied conformity as-
sessment procedure.This declaration of conformity can be provided on re-
quest.
−To ensure appropriate use, only use the regulator in applications where the
operatingpressureandtemperaturesdonotexceedthespecicationsused
for sizing the regulator at the ordering stage.
−The manufacturer does not assume any responsibility for damage caused by
external forces or any other external factors.
−Any hazards that could be caused in the regulator by the process medium,
operating pressure or by moving parts are to be prevented by taking appro-
priate precautions.
−Proper transport, storage, installation, operation and maintenance are as-
sumed.

EB 2517 EN 5
Process medium and scope of application
2 Process medium and scope of application
Pressure regulators for set points from 0.05 to 28bar · Valve nominal sizes DN15 to 100
Nominal pressure PN16 to 40 · Suitable for liquids, gases and vapors up to 350°C
The valve opens when the upstream pressure rises.
NOTICE
The Type41-73 Excess Pressure Valve is not a safety valve. If necessary, a suitable
overpressure protection must be installed on site in the plant section.
2.1 Transportation and storage
The regulator must be carefully handled, transported and stored. Protect the regulator against
adverseinuences,suchasdirt,moistureorfrostbeforeitisinstalled.
When regulators are too heavy to be lifted by hand, fasten the lifting sling at a suitable place
on the valve body.
NOTICE
Do not attach any lifting equipment, slings or supports to mounting parts, such as the
adjusting screw or control line.
3 Design and principle of operation
See Fig.1 on page7.
TheType41-73ExcessPressureValveconsistsofaType2417OpeningValveanda
Type2413Actuator.Thevalveandactuatoraredeliveredseparatelyandmustbeassembled
accordingtotheinstructionsinsection4.1.
The excess pressure valve is used to maintain the pressure upstream of the valve to an adjust-
ed set point.
Theprocessmediumowsthroughthevalvebetweenseat(2)andplug(3)inthedirectionin-
dicatedbythearrowonthebody.Thepositionofthevalveplugdeterminestheowrate
and the pressure ratio across the valve. The plug stem is sealed by a frictionless bellows

6 EB 2517 EN
Installation
(5.1).Theupstreampressurep1is transmit-
tedthroughthecompensationchamber(18)
andcontrolline(17)totheoperatingdia-
phragm(12)whereitisconvertedintoapo-
sitioning force. For actuator versions with a
bellows, the pressure is transmitted to the op-
eratingbellows(12.1).Thepositioningforce
is used to move the valve plug according to
theforceofthepositioningsprings(7).The
spring force is adjustable at the set point ad-
juster(6).ValveswithKVS4 and higher fea-
tureabalancingbellows(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 pro-
duced by the upstream and downstream
pressures acting on the plug are balanced.
Depending on the valve and actuator used,
the regulator can be upgraded to create a
safety excess pressure valve.
4 Installation
4.1 Assembly
See Fig.1 on page7.
Valve and actuator can be assembled before
or after the valve has been installed in the
pipeline.
Pushthediaphragmactuator(10)withactu-
atorstem(11)throughtheholeinthecross-
beam(8)ontothespigotsofthebellows
(5.1).Alignitandfastenwithnuts(width
acrossats16,9)ontothevalveange(ap-
prox.25Nm).
For metal bellows actuators in DN15 to 50,
removethecrossbeam(8)fromthevalve.
Pushtheactuatorstem(11)ontothespigots
ofthebellows(5.1).Alignthepillars(8.1)
andfastenwithnuts(widthacrossats24,
8.2)totheactuator(max.60Nm).
For metal bellows actuators in DN65 to
100,removethecrossbeam(8)fromthe
valveandunscrewthepillars(8.1).Screw
thepillarsintothethreadedholes(8.3)ofthe
actuatorangeasfarastheywillgo.Push
theactuatorwithactuatorstem(11)ontothe
spigotsofthebellows(5.1).Fastenthepillars
withnuts(widthacrossats24,8.2)ontothe
valveange(max.60Nm).
1 Valve body
2 Seat
3 Plug
4 Balancing bellows
5 Plug stem
5.1 Bellows
6 Set point adjuster
7 Set point springs
8 Bracket
8.1 Pillar
8.2 Nuts for pillars
8.3 Tapped holes
9 Fastening nuts
10 Diaphragm actuator
11 Actuator stem
12 Operatingdiaphragm
12.1Operatingbellows
13 Diaphragm plate
14 Nut
15 Nuts and bolts
16 Control line connection G ¼ (for steam including
screwjointwithrestriction)
17 Control line installed on site (control line kit available
for tapping the pressure directly at the valve body,
seeT2595)
18 Compensation chamber
19 Filler plug

EB 2517 EN 7
Installation
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
12.1
16
8.2
8.3
Fig.1: Functional diagram
ActuatorforDN65to100
Type2413Actuatorwithmetalbellowsfor2to6bar,5to10bar,10to22barand20to28bar
DN15to50
Type 2417 Valve
Type2413 Diaphragm
Actuator
Pillars turned by
90° in the
drawing
Type41-73Regulator·DN32to100·Withbalancingbellows

8 EB 2517 EN
Installation
4.2 Mounting position
NOTICE
Protect the regulator from icing up
when controlling media that can
freeze. Remove the regulator from
the pipeline when the plant is shut
down if the regulator is not installed
areas free from frost.
Flush the pipeline thoroughly before install-
ing the regulator to ensure that any sealing
parts, weld spatter and other impurities car-
ried along by the process medium do not im-
pair the proper functioning of the valve,
above all the tight shut-off.
NOTICE
Install a strainer (e.g. SAMSON
Type2) upstream of the regulator.
Install the excess pressure valve in horizontal
pipelines.Oninstallingthevalve,makesure
thedirectionofowcorrespondswiththear-
row on the body. For media with a tendency
to condensate, install the pipeline with a
slight downward slope on both sides so that
the condensate can drain properly. If the
pipeline upstream and downstream of the
valve run vertically upwards, an automatic
waterdrainage(e.g.SAMSONType13E
SteamTrap)isrequired.Chooseaplaceof
installation that allows you to freely access
the regulator even after the entire plant has
been completed. The regulator must be in-
stalled free of stress. If necessary, support
thepipeneartheconnectinganges.
Standard mounting position
For gases, liquids and steam
Alternative mounting position
For Gases and liquids at medi-
um temperature up to 80°C
Not for steam
Notpermissible1)
1) Installation in this position on
request
Fig.2: Mounting position
NOTICE
Do not attach supports directly to the
valve or actuator.
If a bypass line is to be used, it must be con-
nected upstream of the pressure tapping
point. Install a shut-off valve in the bypass
line.
Note:
Do not install any instruments (e.g.
temperature regulators or shut-off
valves) that restrict the cross-section
of the pipe between the pressure tap-
ping point and the valve.


EB 2517 EN 9
Installation
4.3 Control line, compensation
chamber and needle valve
Control line · A control line must be provid-
ed at the site of installation, e.g. a
3
/
8
“ pipe
forsteamoran8x1or6x1mmpipefor
air/water.
Connect the control line to the upstream line
(p1)atleastonemeterawayfromthevalve
inlet.
Weld the control line at the side in the mid-
dle of the pipe, inclining at a ratio of ap-
proximately 1:10 up to the compensation
chamber.
Control line kit · A control line kit for tap-
ping pressure directly at the valve body is
available as an accessories part from SAM-
SON.
Compensation chamber(seeTable1)·A
compensation chamber is required for liq-
uidsabove150°Caswellasforsteam.The
mounting position of the compensation
chamber is indicated by an adhesive label
on the chamber itself as well as by an arrow
and the word "top" stamped on the top of
the chamber.
Fig.3: Example of installation with steam
Table1: Assignment of compensation chamber (4) to
regulator
Type2413 Actuator
Actuator area A
Item no.∙Compensation chamber
DN15 to 50 DN65 to 250
640cm² 1190-8789 1190-8790
320cm² 1190-8788 1190-8789
160,80,40cm² 1190-8788
1 Shut-off valve
2 Upstream pressure gauge
3 Strainer
4 Compensation chamber
5 Excess pressure valve
6 Downstream pressure gauge
7 Shut-off valve
1234567

10 EB 2517 EN
Installation
Thismountingpositionmustbeadheredto;
otherwise the safe functioning of the excess
pressure valve cannot be guaranteed.
Weld the line coming from the pressure tap-
ping point to the
3
/
8
“ pipe socket on the
chamber. Install the compensation chamber
at the highest point of the pipeline. Conse-
quently, the control line between compensa-
tion chamber and actuator must also be in-
stalled with a downward slope. In this case,
use a
3
/
8
“pipewithscrewttings.
If the control line connection is located below
themiddleofthevalveinletange,arrange
the compensation chamber at the same level
astheinletange.Inthiscase,useapipe
which is at least ½“ in size for the control
line from the tapping point to the compensa-
tion chamber.
If the control line is connected above the
middleofthevalveoutletange,installthe
compensation chamber at the same level as
the upstream pressure tapping point. The ad-
ditional pressure of the condensate head
must be compensated for by adjusting the set
point.
Needle valve · If the regulator tends to hunt,
we recommend installing a needle valve at
thecontrollineconnection(16)inadditionto
thestandardSAMSONscrewjointwithre-
striction.
4.4 Strainer (lter)
Install the strainer upstream of the excess
pressurevalve.Thedirectionofowmust
correspondtothearrowonthebody.Thel-
ter element must be installed to hang down-
wards or sideways for applications with
steam. Remember to leave enough space to
removethelterelement.
4.5 Shut-off valve
Install a hand-operated shut-off valve both
upstream of the strainer and downstream of
the regulator. This allows the plant to be shut
down for cleaning and maintenance, and
when the plant is not used for longer periods
of time.
4.6 Pressure gauge
Install a pressure gauge both upstream and
downstream of the regulator to monitor the
pressures prevailing in the plant. Install the
pressure gauge on the upstream side in front
of the upstream pressure tapping point (not
betweenthetappingpointandthevalve).