Samson 44-6 B Service manual

Self-operated Pressure Regulators
Type 44-6 B · Excess Pressure Valve
Mounting and
Operating Instructions
EB 2626-2 EN
Edition November 2010
Type 44-6 B Excess Pressure Valve,
stainless steel body
Type 44-6 B Excess Pressure Valve,
red brass body

2EB 2626-2 EN
Contents
Contents Page
1 Design and principle of operation . . . . . . . . . . . . . . . . . . . . . . 4
1.1 Process medium, application range . . . . . . . . . . . . . . . . . . . . . 4
2 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2.1 Mounting position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2.2 Strainer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2.3 Shut-off valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2.4 Pressure gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
3 Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3.1 Start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3.2 Adjusting the set point . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3.3 Decommissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
4 Maintenance and troubleshooting . . . . . . . . . . . . . . . . . . . . . . 8
4.1 Cleaning and replacing the plug . . . . . . . . . . . . . . . . . . . . . . . 8
4.2 Replacing the operating bellows . . . . . . . . . . . . . . . . . . . . . . . 9
4.3 Replacing the set point spring . . . . . . . . . . . . . . . . . . . . . . . . 9
5 Nameplate. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
6 Service. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
7 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
8 Dimensions and weights . . . . . . . . . . . . . . . . . . . . . . . . . . 13
CAUTION!
Indicates a hazardous situation which, if not
avoided, could result in minor or moderate in-
jury.
NOTICE
Indicates a risk of property damage.
Note! Indicates supplementary explanations,
information and tips.
Definitions of the signal words used in these instructions

EB 2626-2 EN 3
Safety instructions
General safety instructions
Observe the following instructions on installation, start-up and operation of the regulator for
your own safety:
4The regulator is to be mounted, started up or serviced by fully trained and qual-
ified personnel only, observing the accepted industry codes and practices.
Make sure employees or third persons are not exposed to any danger.
All safety instructions and warnings in these mounting and operating instruc-
tions, particularly those concerning assembly, start-up and maintenance, must
be observed.
4According to these mounting and operating instructions, trained personnel re-
fers to individuals who are able to judge the work they are assigned to and rec-
ognize possible dangers due to their specialized training, their knowledge and
experience as well as their knowledge of the applicable standards.
4The regulator fulfils the requirements of the European Pressure Equipment Di-
rective 97/23/EC.
4For appropriate operation, make sure that the regulator is only used in areas
where the operating pressure and temperatures do not exceed the sizing data
specified in the order.
4The manufacturer does not assume any responsibility for damage caused by
external forces or any other external influence!
4Any hazards that could be caused in the regulator by the process medium, the
operating pressure or by moving parts are to be prevented by means of the ap-
propriate measures.
4Proper transport, storage, installation, operation and maintenance are as-
sumed.
Note! Non-electric valve versions whose bodies are not lined with an insulating
material coating do not have their own potential ignition source according to the
risk assessment stipulated in EN 13463-1:2001, section 5.2, even in the rare inci-
dent of an operating fault. Therefore, such valve versions do not fall within the
scope of Directive 94/9/EC.
For connection to the equipotential bonding system, observe section 6.3 of
EN 60079-14:2008, VDE 0165-1.

1 Design and principle of oper-
ation
Also see Fig. 1 on page 5.
The excess pressure valve consists of the
valve (1) including the seat (3), plug (2) and
balancing bellows (6) as well as an actuator
section with operating bellows (5), set point
spring (7) and set point adjuster (8/9).
The excess pressure valve is designed to
maintain the pressure upstream of the valve
constant at the adjusted set point.
In pressureless state, the valve is closed. It is
opened when the upstream pressure exceeds
the adjusted set point. The process medium
flows through the valve in the direction indi-
cated by the arrow on the body. The position
of the valve's plug (2) determines the flow rate
across the area released between the plug
and seat (3), and thus the pressure upstream
of the valve.
The upstream pressure p1to be controlled is
transmitted through a bore (4) in the valve
body to the operating bellows (5) where it is
converted into a positioning force. This force is
used to move the plug depending on the force
of the set point spring (7). The spring force can
be adjusted on the set point adjuster (8/9).
1.1 Process medium, application
range
Type 44-6 B Excess Pressure Valve for gases,
liquids and steam
Max. permissible temperatures:
–Non-flammable gases up to 80 °C
–Liquids up to 150 °C
–Nitrogen up to 200 °C
–Steam up to 200 °C
2 Installation
Thoroughly flush the pipeline before installing
the regulator to remove any sealing parts,
weld spatter and other impurities carried
along by the process medium that may impair
the proper functioning of the valve, above all
its tight shut-off.
Make sure the regulator is mounted free of
stress. If necessary, support the piping near
the connecting flanges. Never attach supports
directly to the valve or actuator.
NOTICE
Install a strainer (e.g. SAMSON Type 2 NI
with 0.25 mm mesh size) upstream of the reg-
ulator (refer to section 2.2).
2.1 Mounting position
Install the regulator with the direction of flow
matching the arrow on the body.
– Installation in any desired po-
sition for liquids and gases
≤150 °C
–Installation in horizontal pipe-
lines with the actuator body
pointing down for steam
≥150 °C (see photo)
NOTICE
Make sure no overheating occurs at the place
of installation due to excessive ambient tem-
peratures or insufficient heat dissipation.
As a result, never insulate red brass bodies
together with the medium pipeline.
4EB 2626-2 EN
Design and principle of operation

EB 2626-2 EN 5
Installation
1 Valve body
1.1 Body gasket
2 Plug
3 Seat
4 Bore for control pressure
5 Operating bellows
6 Balancing bellows (not for 0.2
to 2 bar set point range with
standard plug)
7 Set point spring
8 Set point adjuster
9 Set point screw
10 Screws
11 Screw plug
11.1 Sealing ring
Type 44-6 B · Version with threaded body made of
red brass
7
9
Set point screw
Stainless steel or spheroidal graphite iron version
(DN 40 and 50) and 8 to 20 bar set point range ·
SW 3 or 5 hexagon socket screw (spheroidal
graphite iron)
1
3
2p1p2
6
4
11
(40 Nm)
11.1
1.1
10
(10 Nm)
5
7
8
Fig. 1 · Design and principle of operation, Type 44-6 B
Valve
Actuator housing

2.2 Strainer
Install a strainer upstream of the regulator
(Fig. 2). Install the strainer with the direction
of flow matching the arrow on the body.
In horizontal pipelines, install the strainer with
the filter element pointing down. For steam,
install the strainer with the filter element point-
ing to the side.
In vertical pipelines with the direction of flow
from bottom to top, the drain flange of the fil-
ter element points up. In this case, dirt parti-
cles are not collected, but retained.
Remember to leave enough space to remove
the filter element.
2.3 Shut-off valve
Install a hand-operated shut-off valve both
upstream of the strainer and downstream of
the regulator (Fig. 2) to be able to shut down
the plant for cleaning and maintenance, and
when the plant is not used for longer periods
of time.
2.4 Pressure gauge
To monitor the pressures in the plant, install a
pressure gauge both upstream and down-
stream of the regulator (Fig. 2).
6EB 2626-2 EN
Installation
12 4
351
Fig. 2 · Sample installation scheme
1 Shut-off valve
2 Upstream pressure gauge
3 Strainer
4 Type 44-6 B Excess Pressure Valve
5 Downstream pressure gauge
p1p2

3 Operation
3.1 Start-up
CAUTION!
Do not start up the regulator before all com-
ponents have been installed.
We recommend to open shut-off valves
slowly from the upstream side. Avoid pres-
sure surges.
NOTICE
When pressure-testing the pipelines with the
regulator installed, make sure the regulator is
not damaged by the test pressure.
Make sure the maximum permissible pres-
sure of 1.5 times the nominal pressure PN is
not exceeded.
Protect the regulator against frost when it is
used to control freezing process media (e.g.
water). When the regulator is not used for
longer periods of time, remove it from the
pipeline, if necessary.
3.2 Adjusting the set point
Also see Fig. 1 on page 5.
Adjust the desired set point by turning the set
point adjuster (8) or set point screw (9).
Turn the set point adjuster or screw:
4Clockwise P
to increase the pressure set point
4Counterclockwise Q
to reduce the pressure set point
Version with stainless steel or spheroidal
graphite iron body (DN 40 and 50) and 8 to
20 bar set point range:
1. Loosen the lock nut.
2. Adjust the set point by turning the set
point screw (9) clockwise or counter-
clockwise using an SW 3 or 5 Allen key
(spheroidal graphite iron body).
3. Retighten the lock nut.
Check the adjusted set point on the pressure
gauge installed upstream of the regulator
(Fig. 2).
The set point range can be changed by re-
placing the set point spring (7; refer to sec-
tion 4.3).
3.3 Decommissioning
We recommend to close the upstream shut-off
valve before closing the shut-off valve down-
stream of the regulator.
EB 2626-2 EN 7
Operation

4 Maintenance and trouble-
shooting
The pressure regulator is maintenance free.
Nevertheless, it is subject to natural wear,
particularly at the seat, plug and operating or
balancing bellows.
Depending on the operating conditions,
check the regulator at regular intervals to de-
tect and remove possible malfunctions.
If external leaks occur, check the operating
bellows (refer to section 4.2), and replace it, if
necessary.
Refer to Table 1 to determine the cause of ex-
isting faults and remove them. This may help
to re-establish the regulator's proper func-
tioning.
Note! Refer to Spare Parts List EL 2626 for
original spare parts to be ordered from
SAMSON (refer to section 6).
CAUTION!
For installation and maintenance work on the
regulator, depressurize the relevant plant sec-
tion and, depending on the process medium,
drain it as well. We recommend to remove the
regulator from the pipeline.
If necessary, allow the regulator to cool down
to reach ambient temperature before starting
any work on it.
As valves are not free of cavities, remember
that residual process medium might still be
contained in the valve.
4.1 Cleaning and replacing the
plug
Also see Fig. 1 on page 5.
Use a socket wrench (order no. 1280-3001)
to remove the screw plug (11). This wrench
can also be made, for example from a screw-
driver bit (IN 19-19) by boring a
17-mm-deep hole (Ø 17) into the 19 mm
hexagon bit as shown in Fig. 3.
1. Relieve the set point spring (7) by turn-
ing the set point adjuster (8/9) counter-
clockwise Q.
2. Unscrew the screw plug (11). Pull out the
balancing bellows (6) together with the
plug (2) and plug stem.
3. Thoroughly clean the seat and plug.
If the plug or balancing bellows are
damaged, replace the entire assembly
(remember that there is no balancing
bellows with the standard plug for 0.2 to
2 bar set point range).
4. Replace the sealing ring (11.1) with a
new one.
5. For assembly, proceed in reverse order.
Observe the tightening torques given in
Fig. 1.
8EB 2626-2 EN
Maintenance and troubleshooting
17
Ø 17
SW 19
Fig. 3 · Socket wrench as special tool

4.2 Replacing the operating bel-
lows
Also see Fig. 1 on page 5.
1. Relieve the set point spring (7) by turn-
ing the set point adjuster (8/9) counter-
clockwise Q.
CAUTION!
Be careful when loosening the screws as the
set point spring is still slightly pretensioned.
2. Unscrew the screws (10) evenly.
3. Remove the lower actuator section includ-
ing set point spring (7) and operating bel-
lows (5).
4. Remove the operating bellows and re-
place it with a new one.
5. Replace the body gasket (1.1) with a
new one.
6. For assembly, proceed in reverse order.
Observe the tightening torques given in
Fig. 1.
4.3 Replacing the set point
spring
Also see Fig. 1 on page 5.
The set point spring is located in the actuator
housing. Remove the actuator housing from
the valve to replace the spring.
1. Fully relieve the set point spring (7) by
turning the set point adjuster (8/9) coun-
terclockwise Qall the way.
CAUTION!
Be careful when loosening the screws as the
set point spring is still slightly pretensioned.
2. Unscrew the screws (10) evenly.
3. Remove the lower actuator section in-
cluding set point spring (7) and operat-
ing bellows (5).
4. Remove the set point spring and replace
it with a new one.
5. Replace the body gasket (1.1) with a
new one, if necessary.
6. For assembly, proceed in reverse order.
Observe the tightening torques given in
Fig. 1.
EB 2626-2 EN 9
Maintenance and troubleshooting

Table 1 · Troubleshooting and fault removal
Fault Possible cause Remedy
Pressure exceeds
the adjusted set
point
Insufficient pressure pulse on the oper-
ating bellows Connect control line in special version without control line. Clean control line
and screw joint.
Pressure tapped in wrong location in
special version with external control
line
Reroute control line. Do not connect it
to pipe elbows or necks.
Wear on seat and plug due to deposits
or foreign particles Replace damaged parts.
Plug blocked by foreign particles Remove foreign particles. Replace
damaged parts as necessary.
Valve installed against the direction of
flow Check that valve is installed with the direction of flow matching the arrow
on the valve body.
Pressure drops be-
low the adjusted set
point
Plug blocked by foreign particles Remove foreign particles. Replace
damaged parts as necessary.
Jerky control
response Increased friction, e.g. due to foreign particles in seat-plug trim Remove foreign particles. Replace damaged parts as necessary.
Slow control
response Dirt inside control line impedes me- dium flow Clean control line.
Upstream pressure
fluctuates Valve too large Check valve sizing. Change KVS/CV
coefficient or install suitable regulator.
Pressure tapped in wrong location in
special version with external control line Reroute control line. Do not connect it to pipe elbows or necks.
Severe noise
emissions High flow velocity, cavitation Check valve sizing. If necessary, install a larger regulator.
Special operating and installation conditions can lead to changed situations that may affect the
control response and lead to malfunctions. In such cases, check the installation conditions, pro-
cess medium, temperature and pressure conditions. A thorough analysis may require the
on-site assistance of the SAMSON After-sales Service staff (refer to section 6).
10 EB 2626-2 EN
Maintenance and troubleshooting