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.

EB 2723 EN 11
Markings on the device
1.4 Warnings on the regulator
Warning
symbols
Meaning of the warning Location on the device
WARNING
Disassembly of
spring only with
suitable tool.
See EB …
Warning to indicate that the set point springs are
loaded.
There is a risk of serious head or face injury due to the
sudden release of the set point springs while unscrewing
the crossbeam when the set point springs are loaded.
2. Markings on the device
2.1 Regulator nameplate
1 Model number
2Conguration ID (Var.-ID) and device index
3Order number or year of manufacture
4Type designation
5Pressure rating PN
6 KVS coefcient
7 Perm. temperature in °C
8 Set point range in bar
9Max. perm. differential pressure Δp in bar
10 Arrow indicating the direction of ow
123
45
6107
8 9
Fig.1: Nameplate
2.2 Location of the nameplate
Nameplate
position on
the body
Fig.2: Nameplate on the bodies

12 EB 2723 EN
Design and principle of operation
2.3 Material identication
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.
2.4 Warning
The red adhesive labels indicate hazards
that may arise while working on the regula-
tor. Risk of personal injury.
ÎObserve the warnings.
3. Design and principle of oper-
ation
ÎSee Fig.3
The regulator are closed when relieved of
pressure. They open when the upstream
pressure rises above the adjusted set point.
The Type44-4 and Type44-7 Excess Pres-
sure Valves mainly consist of the valve (1)
with seat (2) and plug (3) as well as the ac-
tuator with operating diaphragm (6.1), set
point spring (8) and set point adjuster (10).
The excess pressure valve is used to maintain
the pressure upstream of the regulator 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 upstream pressure.
The upstream pressure p1 to be controlled is
transmitted over the control line (11) to the
operating diaphragm (6.1) where it is con-
verted into a positioning force. This force is
used to move the valve plug according to the
force of the set point spring (8). The spring
force can be adjusted at the set point adjust-
er (10).
The Type44-4 Safety Excess Pressure Valve
additionally has a second backup dia-
phragm (6.2). Upon failure of the rst oper-
ating diaphragm (6.1) the regulator is fully
opened. 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 test connection.
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 excess pressure valve and safety excess
pressure valve are designed to maintain the
pressure upstream of the regulator to the ad-
justed set point especially in district heating
systems and extended heating systems.
Type44-4 and Type44-7 are suitable for
controlling liquids and gases.

EB 2723 EN 13
Design and principle of operation
Type44-7 (DN32 to 50), anged valve body
Turned
into the
plane of
projection
p
2
p
1
13
7
1
1.1
3
2
11
17
6
6.1
5
1.2
3.2
16
1.3
3.1
3.3
3.5
15
+
9
10
7
8
Type44-4 SEV DN15 to 25, plug section
5
11
7
6.1
14
12
6.2
3.1
3.4
3.6
3.3
1Valve body
1.1 Stopper
1.2 Seal
1.3 Seal
2 Seat
3 Plug with seal
3.1 Balancing piston
3.2 Plug nut
3.3 Plug stem
3.4 Plug spring
3.5 Plug nipple
3.6 Guide nipple
5Inspection bore
6Actuator housing
6.1 Operating diaphragm
6.2 Backup diaphragm
7Diaphragm stem
8 Set point spring(s)
9 Spring plate
10 Set point adjuster
11 Control line
12 Diaphragm rupture
indicator
13 Housing screws
14 Distance ring
15 Diaphragm plate nut
16 Diaphragm plate
17 O-rings
Fig.3: Functional diagram of Type44-7 Excess Pressure Valve as well as Type44-4 Safety Excess
Pressure Valve (SEV)

14 EB 2723 EN
Design and principle of operation
− Max. permissible temperatures for gases
up to 80°C
− Air/nitrogen up to 80°C1)
− Liquids up to 150°C
The regulator is closed when relieved of
pressure. It opens when the upstream pres-
sure rises above the adjusted set point.
Type test
The Type44-4 Regulator has been typetested
as a safety excess pressure valve (SEV) by
the German technical surveillance associa-
tion TÜV.
The test mark is available on request.
1) With seals made of FKM
Temperature range
The Type44-4 and Type44-7 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 emissions
SAMSON is unable to make general state-
ments about noise emissions. The noise emis-
sions depend on the regulator version, plant
facilities, process medium and operating
conditions.
Risk of hearing loss or deafness due to loud
noise.
− Wear hearing protection when working
near the valve. Follow the instructions giv-
en by the plant operator.
Dimensions and weights
Table4 provides a summary of the dimen-
sions and weights of the Type44-4 and
Type44-7 Regulators. The lengths and
heights in the dimensional drawings are
shown on page17 onwards.
WARNING
!

EB 2723 EN 15
Design and principle of operation
Table1: Technical data · All pressures in bar (gauge)
Regulator Excess pressure valve
44-7 44-4 (SEV)
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) 80°C
Max. permissible differential pressure ∆p 11bar
Set point range (continuously
adjustable)
Type44-7 1 to 4bar·2 to 4.4bar·2.4 to 6.6bar·6 to 11bar
Type44-4 (SEV) 1 to 4bar2)·2 to 4.4bar·2.4 to 6.6bar·6 to 11bar
Leakage class according to IEC60534-4 ≤0.05% of KVS coefcient
Conformity ·
Max. perm. ambient temperature 60°C
1) With seals made of FKM; without type test (Type44-4)
2) Special version, without type test
Table2: Materials · Material numbers according to DIN EN
Body Red brass CC499K Spheroidal graphite iron
EN-GJS-400-18-LT
Seat 1.4305
Plug Brass CW602N 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

16 EB 2723 EN
Design and principle of operation
Table3: KVS coefcients
Body with screwed ends
Valve size DN 15 20 25 32 40 50
KVS coefcients Standard version 2.5 6.3 8.0 12.5 16.0 20.0
Special version 1.0·4.0 —
xFz values 0.60 0.55 0.5 0.45
Flanged body
Valve size DN DN32 DN40 DN50
KVS coefcients 12.5 20.0 25.0
xFz values 0.55 0.5 0.45
Table4: Dimensions · Weights
Valve size DN 15 20 25 32 40 50
Length Lmm 65 70 75 100 110 130
Pipe Ø d mm 21.3 26.8 33.7 42.0 48.0 60.0
Connection RG¾ G1 G1¼ G1¾ G2 G2½
Width across ats SW mm 30 37 46 60 65 82
Height HType44-7 mm 2282) 2522) 380
Type44-4 mm 2481) 2721) 410
Height H1 mm 41 55 56
Height H2 mm 32 45
Actuator housing ØD mm 116 160
X mm 36
Version with welding ends
Length L1 mm 210 234 244 268 294 330
Weight kg (approx.) 3.6 3.7 4.1 5.7 11.8 14.2
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.) 3.5 3.6 4.0 5.5 11.5 13.8
Version with screwed-on anges or with anged body (DN32 to 50 only)
Length L3 mm – 180 200 230
Weight kg (approx.) –8.7 15.8 17.6
1) 273mm with 6 to 11bar set point range 2) Set point range 6 to 11bar: H + +19mm

EB 2723 EN 17
Design and principle of operation
Dimensional drawings
Version with welding ends
Type44-7·Body: CC499K Type44-4·Body: CC499K
L
L 1
ØD
SW
RØd
H
H1
ØD
L
X
L 1
SW
R
H1
H2
Ød
H
Version with anged valve body
Type44-4 and Type44-7
Body: spheroidal graphite iron1) Version with threaded ends
L3
L 2
SW
RA
H1
Fig.4: Dimensions
1) DN32, 40 and 50

18 EB 2723 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 the storage instructions.
− Avoid long storage times.
− Contact SAMSON in case of different
storage conditions or longer storage times.
We recommend to regularly check the device
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 2723 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
1234 51
p
1p
2
1Shut-off valve
2Upstream pressure gauge
3Strainer (Type44-7 only)
4 Excess pressure valve
5 Downstream pressure gauge
Fig.5: Pressure control with Type44-7 (installation example)
Type44-
9 SSV
+
+
Type44-
4 SEV
Fig.6: Protection of a house substation with
SSV and SEV

20 EB 2723 EN
Mounting
5. Mounting
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 regula-
tor and leakage at the joint due to installa-
tion under tension.
− Bolt the regulator to the pipeline free of
stress.
− If necessary, support the pipelines near the
connections.
− Do not attach supports directly to the regu-
lator.
NOTICE
!NOTICE !
NOTICE
!
5.1 Mounting positions
Install Type44-4 and Type44-7 Regulators
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 (Type44-7 only). 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.
Possible malfunction and damage due to
adverse weather conditions (temperature,
humidity).
− Do not install the device outdoors or in
rooms prone to frost.
− Protect the regulator against frost if it is
used to control freezing media.
− Either heat the regulator or remove it from
the plant and completely drain the residual
medium after a plant shutdown.
NOTICE
!