Samson 44-2 Service manual

Translation of original instructions
EB 2623-1 EN
Edition August 2018
Type44-3 Safety Pressure Reducing Valve (SSV)
Red brass body with screwed ends
Type44-2 Pressure Reducing Valve
Type44-3 and Type44-9 Safety Pressure Reducing Valves (SSV)

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 2623-1 EN

Contents
EB 2623-1 EN 3
1 Safety instructions and measures ...................................................................5
1.1 Notes on possible severe personal injury .........................................................7
1.2 Notes on possible personal injury ...................................................................8
1.3 Notes on possible property damage ................................................................9
2 Markings on the device ...............................................................................10
2.1 Regulator nameplate ....................................................................................10
2.2 Material number ..........................................................................................11
3 Design and principle of operation ................................................................12
3.1 Technical data .............................................................................................14
4 Measures for preparation............................................................................18
4.1 Unpacking ..................................................................................................18
4.2 Transporting and lifting ................................................................................18
4.3 Storage .......................................................................................................18
4.4 Preparation for installation ............................................................................19
5 Mounting and start-up.................................................................................20
5.1 Mounting positions .......................................................................................20
5.2 Additional ttings .........................................................................................21
5.3 Start-up .......................................................................................................22
5.4 Gases and liquids ........................................................................................22
6 Operation...................................................................................................22
6.1 Adjusting the set point ..................................................................................22
7 Servicing.....................................................................................................23
7.1 Cleaning and replacing the seat and plug ......................................................24
7.2 Exchanging the operating diaphragm ............................................................26
7.3 Replacing the set point springs ......................................................................28
7.4 Tightening torques and lubricant ...................................................................29
7.5 Preparation for return shipment .....................................................................30
7.6 Ordering spare parts and operating supplies .................................................30
8 Malfunctions ...............................................................................................30
9 Decommissioning and removal ....................................................................33

Contents
4 EB 2623-1 EN
9.1 Decommissioning .........................................................................................33
9.2 Disposal ......................................................................................................33
10 Annex.........................................................................................................34
10.1 After-sales service ........................................................................................34
10.2 Spare parts .................................................................................................34
10.3 Certicates ..................................................................................................37

EB 2623-1 EN 5
Safety instructions and measures
1 Safety instructions and measures
Intended use
The SAMSON Type44-2, Type44-3 and Type44-9 Pressure Regulators are suitable for
pressure control of liquids and gases. 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
−Changing parts, service or repair work on TÜV-tested Type44-3 and Type44-9
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.
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.

6 EB 2623-1 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.
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 2623-1 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 Annex 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).
1.1 Notes on possible severe personal injury
DANGER
!
Risk of bursting in pressure equipment.
Regulators and pipelines are pressure equipment. Improper opening can lead to regu-
lator components bursting.
ÎIf necessary, a suitable overpressure protection must be installed on site in the plant
section.
ÎBefore starting any work on the regulator, depressurize all plant sections
concerned.
ÎDrain the process medium from all the plant sections concerned as well as the reg-
ulator.
ÎWear personal protective equipment.

8 EB 2623-1 EN
Safety instructions and measures
1.2 Notes on possible personal injury
WARNING
!
Risk of personal injury due to preloaded springs.
Regulators in combination with preloaded set point springs are under tension. These
regulators can be identied by the red warning label on the actuator's set point springs.
ÎBefore starting any work on the springs, relieve the compression from the preloaded
springs.
ÎOnly use the SAMSON disassembly tool (1280-4052).
Crush hazard arising from moving parts.
The regulator contains moving parts (actuator and plug stems), which can injure hands
or ngers if inserted into the valve.
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.
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.
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.
ÎInformation on safe use of the part affected, see uwww.samson.de/reach-en.html.

EB 2623-1 EN 9
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.
ÎObserve the maximum permissible pressure for regulator and 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.
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.
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 can support you concerning lubricant, tightening torques
and tools approved by SAMSON.
Note

10 EB 2623-1 EN
Markings on the device
2 Markings on the device
2.1 Regulator nameplate
1Model number
2 Conguration ID (Var.-ID) and device index
3 Order number or year of manufacture
4 Type designation
5Pressure rating PN
6 KVS (CV) coefcient
7Perm. temperature in °C
8Set point range in bar
9Max. perm. differential pressure Δp in bar
10 Arrow indicating the direction of ow
12 3
45
6 10 7
8 9
Fig.1: Nameplate
The nameplate of all sizes is afxed to the
body (see Fig.2).
Nameplate
position on
the body
Fig.2: Nameplate on the bodies

EB 2623-1 EN 11
Markings on the device
2.2 Material number
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 (2 (conguration ID and device index).
For more details on the nameplate, see sec-
tion2.1.

12 EB 2623-1 EN
Design and principle of operation
The Type44-3 Safety Pressure Reducing
Valve additionally has a second backup
diaphragm (126). Upon failure of the rst
operating diaphragm (125) the regulator
continues to function using the backup
diaphragm (126). In this case, the regulator
functions as a safety valve when the
downstream pressure rises too far and closes
the valve. Diaphragm failure is indicated by
a red mark in the diaphragm rupture
indicator (12) (point of response at approx.
1.5bar) or medium escapes at the
inspection bore.
The Type44-9 Safety Pressure Reducing
Valve additionally has a second backup dia-
phragm (126). Upon failure of the rst oper-
ating diaphragm (125) the regulator is com-
pletely closed. Diaphragm failure is indicat-
ed by a red mark in the diaphragm rupture
indicator (12) (point of response at approx.
1.5bar) or medium escapes at the inspec-
tion bore.
3 Design and principle of oper-
ation
ÎRefer to Fig.3
The regulators are open when relieved of
pressure.
They close when the downstream pressure
rises above the adjusted set point.
The Type44-2, Type44-3 and Type44-9
Pressure Reducing Valves mainly consist of
the valve body (30) with seat (35) and plug
(2) as well as the actuator with operating di-
aphragm (125), set point springs (70…78)
and set point adjuster (56).
The pressure reducing valve is used to main-
tain the pressure downstream of the valve to
an adjusted set point.
The process medium ows through the regu-
lator between seat and plug in the direction
indicated by the arrow on the body. The po-
sition of the valve plug determines the ow
rate and, as a result, the downstream pres-
sure.
The downstream pressure p2 to be controlled
is transmitted over the control line (116) to
the operating diaphragm (125) where it is
converted into a positioning force. This force
is used to move the valve plug according to
the force of the set point springs (70…78).
The spring force is adjustable at the set point
adjuster (56).

EB 2623-1 EN 13
Design and principle of operation
30
4
116
2
2.4
2.1
125
112
83
57
90
70…78
95
56
2.6
58
p
1p2
35
17
134
130
112
126
83
125
116
237
12
90
57
130
28
Type44-9 SSV
30
2
2.1
28
12
116
83
237
112
130
27
126
125
2.6
35
134
Type44-2 (DN15 to 25)
Body with screwed ends
2 Plug with plug seal
2.1 Balancing piston
2.4 Plug spring
2.6 Guide nipple
4 Coupling nut
12 Diaphragm rupture indicator
17 O-rings
27 Plug nipple
28 Screw plug for the inspection
bore
30 Valve body
35 Seat
56 Set point adjuster
57 Diaphragm plate nut
58 Lock nut
70…78 Set point spring(s)
83 Diaphragm stem
90 Diaphragm plate
95 Spring plate
112 Actuator housing
116 Control line
125 Operating diaphragm
126 Backup diaphragm
130 Housing screws
134 Seal
237 Distance ring
Type44-3 (DN32 to 50)
Version with anged valve body
Fig.3: Functional diagram of Type44-2 Pressure Reducing Valve as well as Type44-3 and Type44-
9 Safety Pressure Reducing Valves (SSV)

14 EB 2623-1 EN
Design and principle of operation
3.1 Technical data
The regulator's nameplate contains informa-
tion on the regulator version (see sec-
tion2.1).
Process medium and scope of application
The (safety) pressure reducing valves are de-
signed to maintain pressure downstream of
the regulator to the adjusted set point district
heating systems or large heating networks.
Type44-2, Type44-3 and Type44-9 are
suitable for controlling liquids and gases.
−Max. permissible temperatures for gases
up to 80°C
−Air/nitrogen up to 150°C1)
−Liquids up to 150°C
The regulator is open when relieved of pres-
sure. It closes when the downstream pressure
rises above the adjusted set point.
Type test
The Type44-3 and Type44-9 Regulators
have been typetested as safety pressure re-
ducing valves (SSV) by the German Techni-
cal Inspectorate (TÜV).
The test mark is available on request.
1) With seals made of FKM
Temperature range
The Type44-2, Type44-3 and Type44-9
Regulators are designed for a temperature
range from 0 to +150°C.
Leakage class
All regulators have the leakage class I ac-
cording to IEC60534-4.
Noise emission
SAMSON is unable to make general state-
ments about noise emission as it depends on
the valve version, plant facilities and process
medium.
Risk of hearing loss or deafness due to loud
noise.
Wear hearing protection when working near
the regulator.
Dimensions and weights
Table4 provides a summary of the dimen-
sions and weights of the Type44-2, Type44-
3 and Type44-9 Regulators. The lengths and
heights in the dimensional drawings are
shown on page17 onwards.
WARNING
!

EB 2623-1 EN 15
Design and principle of operation
Table1: Technical data · All pressures in bar (gauge)
Regulator Pressure reducing valve
44-2 44-3 (SSV)·44-9 (SSV)
Connection Red brass body Male thread DN15, 20, 25, 32, 40 and 50
Spheroidal graphite iron body Flanges DN32, 40 and 50
Pressure rating PN 25
Max. permissible
temperature
Liquids 150°C
Non-ammable gases 80°C
Air and nitrogen1) 150°C
Set point range (continuously adjustable) 1 to 4bar3)·2 to 4.2bar 2.4
to 6.3bar·6 to 10.5bar
Leakage class according to IEC60534-4 ≤0.05% of KVS coefcient 2)
Compliance ·
Max. perm. ambient temperature 60°C
1) With seals made of FKM; without type test (Types44-3 and 44-9)
2) Leakage rate = I/bubble-tight applies to EPDM/FKM soft seal.
3) Special version of Type44-3 and Type44-9, without type test
Table2: Materials · Material numbers according to DIN EN
Enclosure Red brass CC499K Spheroidal graphite iron EN-GJS-400-18-LT
Seat 1.4305
Plug 2) Brass 2.0402 and stainless steel 1.4305 with EPDM soft seal 1)
Actuator housing/
intermediate ring Red brass CC499K
Set point spring 1.4310
Operating diaphragm EPDM with fabric reinforcement 1)
Seals EPDM 1)
1) Special version, e.g. for mineral oils: FKM
2) KVS0.4: stainless steel 1.4305

16 EB 2623-1 EN
Design and principle of operation
Table3: KVS coefcients·XFZ values · Max. permissible differential pressure ∆p
Valve size DN 15 20 25 32 40 50
Max. permissible differential pressure ∆p 20bar 12bar
xFz values 0.60 0.55 0.5 0.45
Body with screwed ends
KVS coefcients Standard version 4.0 6.3 8.0 12.5 16.0 20.0
Special version 0.41)·1.0·2.5 –
Flanged body
KVS coefcients Standard version –12.5 20.0 25.0
1) Special version of Type44-2
Table4: Dimensions · Weights
Valve size DN 15 20 25 32 40 50
Length Lmm 65 70 75 100 110 130
Pipe Ød mm 21.3 26.9 33.7 42.4 48.3 60.3
Connection RG¾ G1 G1¼ G1¾ G2 G2½
Width across ats SW mm 30 36 46 59 65 82
Height H
Type44-2 mm 230 250 380
Type44-3 mm 2851) 443
Type44-9 mm 3172) 475 488
Height H1 mm 34 43 45
Actuator housing ØD mm 116 160
Version with welding ends
Length L1 mm 210 234 244 268 294 330
Weight kg (approx.) 2.0 2.1 2.2 8.5 9.0 9.5
Version with threaded ends
Length L2 mm 129 144 159 192 206 228
Male thread A G½ G¾ G1 G1¼ G1½ G2
Weight kg (approx.) 2.0 2.1 2.2 8.5 9.0 9.5
Version with screwed-on anges or with anged body (DN32 to 50 only)
Length L3 mm – 180 200 230
Weight kg (approx.) –11.7 13.0 14.5
1) 310mm with 6 to 10.5bar set point range 2) 355mm with 6 to 10.5bar set point range

EB 2623-1 EN 17
Design and principle of operation
Dimensional drawings
Version with welding ends
Type44-2·Body: CC499K Type44-3·Type44-9·Body: CC499K
SW
L1
L
ØD
H
RØ
d
H1
SW
L1
L
~36
H
RØ
d
H1
ØD
Version with anged valve body
Type44-2, Type44-3 and Type44-9
Body: spheroidal graphite iron1) Version with threaded ends
L3
L2
SW
H1
RA
Fig.4: Dimensions
1) DN32, 40 and 50

18 EB 2623-1 EN
Measures for preparation
4 Measures for preparation
After receiving the shipment, proceed as fol-
lows:
1. Check the scope of delivery. Compare
the shipment received with the delivery
note.
2. Check the shipment for transportation
damage. Report any damage to
SAMSON and the forwarding agent
(refer to delivery note).
4.1 Unpacking
Do not remove the packaging until immedi-
ately before installing the valve into the pipe-
line.
4.2 Transporting and lifting
Due to the low service weight, lifting equip-
ment is not required to lift and transport the
regulator (e.g. to install it into the pipeline).
Transport instructions
−Protect the device against external inu-
ences (e.g. impact).
−Do not damage the corrosion protection
(paint, surface coatings). Repair any
damage immediately.
−Protect the device against moisture and
dirt.
−Observe the permissible ambient tem-
peratures (see section3.1).
Note
4.3 Storage
Risk of regulator damage due to improper
storage.
−Observe storage instructions.
−Avoid long storage times.
−Contact SAMSON in case of different stor-
age conditions or long storage periods.
We recommend regularly checking the de-
vice and the prevailing storage conditions
during long storage periods.
Storage instructions
−Protect the device against external inu-
ences (e.g. impact).
−Do not damage the corrosion protection
(paint, surface coatings). Repair any
damage immediately.
−Protect the device against moisture and
dirt. Store it at a relative humidity of less
than 75%. In damp spaces, prevent con-
densation. If necessary, use a drying
agent or heating.
−Make sure that the ambient air is free of
acids or other corrosive media.
−Observe the permissible ambient tem-
peratures (see section3.1).
−Do not place any objects on the device.
NOTICE
!
Note

EB 2623-1 EN 19
Measures for preparation
Special storage instructions for elastomers
Elastomer, e.g. operating diaphragm
−To keep elastomers in shape and to pre-
vent cracking, do not bend them or hang
them up.
−We recommend a storage temperature of
15°C for elastomers.
−Store elastomers away from lubricants,
chemicals, solutions and fuels.
SAMSON's After-sales Service can provide
more detailed storage instructions on re-
quest.
Tip
4.4 Preparation for installation
Proceed as follows:
ÎFlush the pipelines.
The plant operator is responsible for clean-
ing the pipelines in the plant.
ÎCheck the regulator to make sure it is
clean.
ÎCheck the regulator for damage.
ÎCheck to make sure that the type desig-
nation, valve size, material, pressure rat-
ing and temperature range of the regula-
tor match the plant conditions (size and
pressure rating of the pipeline, medium
temperature etc.).
ÎCheck any mounted pressure gauges to
make sure they function.
Note

20 EB 2623-1 EN
Mounting and start-up
5 Mounting and start-up
Risk of overheating due to excessive ambient
temperatures or insufcient heat dissipation
when components are insulated.
−Do not include the regulator in the insula-
tion of the pipeline.
Risk of impaired functioning of the regulator
and leakage at the joint due to installation
under tension.
−Bolt the regulator to the pipeline free of
stress.
−If necessary, support the pipelines near to
the connections.
−Do not attach supports directly to the regu-
lator.
NOTICE
!NOTICE !
NOTICE
!
5.1 Mounting positions
Install Type44-2, Type44-3 and Type44-9
with the actuator housing suspended down-
ward in horizontal pipelines.
Installation conditions
ÎMake sure that the regulator remains
freely accessible after the plant has been
completed.
ÎInstall a strainer upstream of the regula-
tor (see section5.2).
ÎMake sure the direction of ow matches
the direction indicated by the arrow on
the body.
ÎInstall the regulator free of stress.
ÎThe valves are connected to the pipeline
using threaded ends, welding ends or
anged body.
1234 51
p
1p
2
1Shut-off valve
2 Upstream pressure gauge
3 Strainer
4 Pressure reducing valve
5Downstream pressure gauge
Type44-2 Pressure Reducing Valve
Fig.5: Pressure control with Type44-2 (installation example)