Samson 44-7 Service manual

Translation of original instructions
EB 2723 EN
Type44-7 Excess Pressure Valve
Type44-4 Safety Excess Pressure Valve (SEV)
Self-operated Pressure Regulators
Edition May 2023
Type44-7 Excess Pressure Valve
Red brass body with screwed ends

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 2723 EN
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]).
Documents relating to the device, such as the mounting and operating
instructions, are available on our website at www.samsongroup.com >
Service & Support > Downloads > Documentation.

Contents
EB 2723 EN
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
1.4 Warnings on the regulator............................................................................11
2. Markings on the device ...............................................................................11
2.1 Regulator nameplate ....................................................................................11
2.2 Location of the nameplate.............................................................................11
2.3 Material identication number ......................................................................12
2.4 Warning .....................................................................................................12
3. Design and principle of operation ................................................................12
3.1 Technical data .............................................................................................12
4. Measures for preparation............................................................................18
4.1 Unpacking ..................................................................................................18
4.2 Transporting and lifting ................................................................................18
4.3 Storage.......................................................................................................18
5. Mounting ....................................................................................................20
5.1 Mounting positions.......................................................................................20
5.2 Additional ttings.........................................................................................21
5.3 Preparation for installation............................................................................22
5.3.1 Cleaning the pipeline ...................................................................................22
5.4 Installation...................................................................................................23
5.4.1 Installing the regulator..................................................................................23
5.4.2 Filling the plant............................................................................................23
5.5 Testing the regulator .....................................................................................24
5.5.1 Leakage ......................................................................................................24
5.5.2 Pressure test.................................................................................................25
5.6 Insulation ....................................................................................................25
6. Start-up ......................................................................................................26
6.1 Start-up and putting the device back into operation ........................................27
6.2 Starting up the plant.....................................................................................27
7. Operation...................................................................................................27
7.1 Adjusting the set point..................................................................................27

Contents
EB 2723 EN
8. Servicing.....................................................................................................28
8.1 Cleaning and replacing the seat and plug......................................................29
8.2 Replacing the operating diaphragm ..............................................................31
8.3 Replacing the set point springs......................................................................33
8.4 Tightening torques and lubricant ...................................................................34
8.5 Preparation for return shipment.....................................................................35
8.6 Ordering spare parts and operating supplies .................................................35
9. Malfunctions ...............................................................................................36
10. Decommissioning and removal ....................................................................39
10.1 Decommissioning.........................................................................................39
10.2 Disposal......................................................................................................40
11. Annex.........................................................................................................41
11.1 After-sales service........................................................................................41
11.2 Spare parts .................................................................................................41
11.3 Certicates ..................................................................................................44

EB 2723 EN 5
Safety instructions and measures
1. Safety instructions and measures
Intended use
The SAMSON Type44-4 and Type44-7 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 applications or conditions other than those specied, contact SAMSON.
SAMSON does not assume any liability for damage resulting from the failure to use the
device 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
− Modication of parts as well as service or repair work on the TÜV-tested Type44-4
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 spe-
cialized training, their knowledge and experience as well as their knowledge of the applica-
ble standards.

6 EB 2723 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).
ÎProvide protective equipment (e.g. safety gloves, eye protection) appropriate for the pro-
cess medium used.
Wear hearing protection when working near the valve. Follow the instructions given by the
plant operator.
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. Plant op-
erators and operating personnel must observe all hazard statements, warnings and caution
notes in these mounting and operating 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 substances database).
ÎObserve safety measures for handling the device as well as re prevention and explosion
protection measures.
Responsibilities of the operator
Operators are responsible for proper use 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, 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,

EB 2723 EN 7
Safety instructions and measures
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 annex of these instructions (see section11.3).
According to the ignition hazard assessment performed in accordance with Clause5.2 of
ISO80079-36, 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
Directive 2014/34/EU.
ÎFor connection to the equipotential bonding system, observe the requirements specied in
Clause6.4 of EN60079-14 (VDE0165-1).
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.
ÎObserve the maximum permissible pressure for regulator and plant.
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 affected.
ÎDrain the process medium from all the plant sections affected as well as the regula-
tor.
ÎWear personal protective equipment.

8 EB 2723 EN
Safety instructions and measures
1.2 Notes on possible personal injury
WARNING
!
Risk of personal injury due to 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 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 set point 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 stem), 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 affected and the
regulator.
ÎWear protective clothing, safety gloves and eye protection.

EB 2723 EN 9
Safety instructions and measures
WARNING
!
Risk of personal injury due to pressurized components and process medium being
discharged.
Incorrect opening of pressure equipment or mounting parts may lead to the process
medium escaping to the atmosphere.
ÎDo not loosen the control line while the valve is pressurized.
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.
Damage to health relating to the REACH regulation.
If a SAMSON device contains a substance listed as a substance of very high concern on
the candidate list of the REACH regulation, this is indicated on the SAMSON delivery
note.
ÎInformation on safe use of the part affected: go to uwww.samsongroup.com > About
SAMSON > Material Compliance > REACH.
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.

10 EB 2723 EN
Safety instructions and measures
NOTICE
!
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.
Risk of regulator damage due to incorrectly attached slings.
ÎDo not attach load-bearing slings to the actuator housing.
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 the equipment.
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.
Risk of leakage and regulator damage due to excessively high or low tightening
torques.
Observe the specied torques when tightening regulator components. Excessive tighten-
ing torques lead to parts wearing out more quickly. Parts that are too loose may cause
leakage.
ÎObserve the specied tightening torques. See section8.4.
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.