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