Samson 33-1 Service manual

Translation of original instructions
EB 2551-1 EN
Edition November 2019
Type 33-1 Safety Shut-off Valve with Pressure Reducing Valve
Self-operated Pressure Regulators

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
Department ([e-mail]).
The mounting and operating instructions for the devices are included in
the scope of delivery. The latest documentation is available on our web-
site at www.samsongroup.com > Service & Support > Downloads > Doc-
umentation.
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 2551-1 EN

Contents
EB 2512 EN
1 Safety instructions and measures ................................................................1-1
1.1 Notes on possible severe personal injury ......................................................1-4
1.2 Notes on possible personal injury ................................................................1-4
1.3 Notes on possible property damage.............................................................1-6
2 Markings on the device ..............................................................................2-1
2.1 Nameplate.................................................................................................2-1
2.2 Nameplate position.....................................................................................2-1
2.3 Material numbers........................................................................................2-1
3 Design and principle of operation ...............................................................3-1
3.1 Additionalttings........................................................................................3-3
3.2 Technical data ............................................................................................3-4
4 Shipment and on-site transport ...................................................................4-1
4.1 Accepting the delivered goods .....................................................................4-1
4.2 Removing the packaging from the regulator ..................................................4-1
4.3 Transporting and lifting the regulator............................................................4-2
4.3.1 Transporting the regulator............................................................................4-2
4.3.2 Lifting the regulator.....................................................................................4-3
4.4 Storing the regulator ...................................................................................4-4
5 Mounting and assembly .............................................................................5-1
5.1 Installation conditions..................................................................................5-1
5.2 Preparation for installation...........................................................................5-2
5.3 Installation..................................................................................................5-4
5.3.1 Installing the regulator.................................................................................5-4
5.3.2 Cleaning the pipeline ..................................................................................5-4
5.4 Checking the regulator ................................................................................5-5
5.4.1 Leak test.....................................................................................................5-6
5.4.2 Pressure test................................................................................................5-6
5.5 Insulation ...................................................................................................5-7
6 Start-up .....................................................................................................6-1
6.1 Start-up and putting the regulator back into operation ...................................6-2
6.2 Starting up the plant....................................................................................6-2
7 Operation..................................................................................................7-1
7.1 Adjusting the set point.................................................................................7-1
8 Malfunctions ..............................................................................................8-1
8.1 Troubleshooting ..........................................................................................8-1
8.2 Emergency action .......................................................................................8-2

Contents
EB 2512 EN
9 Servicing....................................................................................................9-1
9.1 Preparing the valve for service work.............................................................9-2
9.2 Install the regulator after service work...........................................................9-2
9.3 Service work...............................................................................................9-2
9.3.1 Cleaningorreplacingthelterinthepilotvalve............................................9-2
9.3.2 Replacing the seat and plug.........................................................................9-3
9.3.3 Replacing the operating diaphragm .............................................................9-3
9.4 Ordering spare parts and operating supplies ................................................9-4
10 Decommissioning .....................................................................................10-1
11 Removal ..................................................................................................11-1
11.1 Removing the regulator from the pipeline....................................................11-1
12 Repairs ....................................................................................................12-1
12.1 Returning devices to SAMSON ..................................................................12-1
13 Disposal...................................................................................................13-1
14 Certicates...............................................................................................14-1
15 Annex......................................................................................................15-1
15.1 Tightening torques.....................................................................................15-1
15.2 Lubricant..................................................................................................15-1
15.3 Tools ........................................................................................................15-1
15.4 Accessories ..............................................................................................15-1
15.5 Spare parts ..............................................................................................15-2
15.6 After-sales service.....................................................................................15-2

EB 2551-1 EN 1-1
Safety instructions and measures
1 Safety instructions and measures
Intended use
TheSAMSONType33-1Regulatorisasafetyshut-offvalvewithpressurereducingvalve.
The self-operated regulator is used to control the downstream pressure p2in the pipeline to
the adjusted set point. Liquids and gases in processing and industrial plants can be con-
trolled by the regulator.
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additionalttings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33-1
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.Accord-
ing 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appli-
cable standards.

1-2 EB 2551-1 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).Dependingontheprocessmediumand/or
the activity, the protective equipment required includes:
−Protectiveclothing,safetyglovesandeyeprotectioninapplicationswithhot,coldand/or
corrosive media
−Wear hearing protection when working near the valve
−Hard hat
−Safety harness when working at height
−Safety footwear, ESD (electrostatic discharge) footwear, if necessary
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orbymovingpartsbytakingappropriateprecautions.Theymustobserveallhaz-
ard statements, warning and caution notes in these mounting and operating instructions.
Hazardsresultingfromthespecialworkingconditionsattheinstallationsiteoftheregulator
mustbeidentiedinariskassessmentandpreventedthroughthecorrespondingsafetyin-
structions drawn up by the operator.
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.
Safety features
TheType33-1Regulatorisasafetyshut-offvalve(SSV)withpressurereducingvalve.When
relieved of pressure, the regulator is closed by the force of the set point springs in the actua-
tor.

EB 2551-1 EN 1-3
Safety instructions and 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.
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'Certicates'section.
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
Directive 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).
Referenced documentation
The following documents apply in addition to these mounting and operating instructions:
−Mounting and operating instructions for
e.g. Type2NIStrainer uEB1015
−Data sheets for
e.g Type2NIStrainer uT1015
−Mountingandoperatinginstructionsaswellasdatasheetsforadditionalttings
(e.g. shut-off valves, pressure gauges etc.).

1-4 EB 2551-1 EN
Safety instructions and measures
1.1 Notes on possible severe personal injury
DANGER
!
Risk of bursting in pressure equipment.
Regulators and pipelines are pressure equipment. Impermissible pressure or improper
opening can lead to regulator components bursting.
ÎObserve the maximum permissible pressure for regulator and plant.
ÎBeforestartinganyworkontheregulator,depressurizeallplantsectionsaffected
as well as the regulator.
ÎDrain the process medium from all the plant sections affected as well as the regula-
tor.
1.2 Notes on possible personal injury
WARNING
!
Risk of personal injury through 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 hearing loss or deafness due to loud noise.
The noise emissions depend on the valve version, plant facilities and process medium.
ÎWear hearing protection when working near the valve.

EB 2551-1 EN 1-5
Safety instructions and measures
WARNING
!
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 indi-
cated on the SAMSON delivery note.
ÎInformation on safe use of the part affected. uhttp://www.samson.de/reach-en.
html
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.

1-6 EB 2551-1 EN
Safety instructions and measures
1.3 Notes on possible property damage
NOTICE
!
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.
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.
SAMSON's After-sales Service can support you concerning lubricants approved by
SAMSON.
Note

EB 2551-1 EN 2-1
Markings on the device
2 Markings on the device
2.1 Nameplate
Nameplate
21347
9111310 128
Var.-IDK
VS m³/h
PN DN
bar
°C
56
14
DIN/ANSI version
1 Type
2 Pressure rating in PN
3CongurationID
4ValvesizeinDN
5Permissible temperature in
°C
6 KVS coefcient
7Bodymaterial
8 TÜV registration no.
9 P1or P2
10 Set point range
11 Order no.
12 SAP no.:
13 QR code
14 Date of manufacture
Fig.2-1: Nameplates of regulator parts
2.2 Nameplate position
Nameplate
position
Fig.2-2: Nameplate of Type33-1 Regulator
2.3 Material numbers
The material designation can be found on
the nameplate (7, body material) or you can
contactus(thecongurationIDspecication
isneeded)tondoutwhichmaterialisused.
ThecongurationIDisspeciedonthe
nameplate(3,congurationID).Formore
detailsonthenameplate,seesection2.1.

2-2 EB 2551-1 EN
Markings on the device

EB 2551-1 EN 3-1
Design and principle of operation
3 Design and principle of oper-
ation
ÎSeeFig.3-1
TheType33-1SafetyShut-offValve(SSV)
consists of the main valve with actuator and
the pilot valve attached to it.
The safety shut-off valve is used to maintain
the pressure downstream of the main valve
to a set point adjusted at the pilot valve.
The shut-off valve closes when the down-
stream pressure p2rises.
When the shut-off valve starts to open, the
processmediumrstowsthroughthepilot
valve (8) before the main valve (1) opens.
During which, the forces acting on the plug
in the main valve are eliminated by the bal-
ancing bellows (5).
The upstream pressure p1is fed through the
control line (10) to the pilot valve (8) and
serves as the pilot supply pressure. The pilot
valve (8) creates a control pressure pS. It
functions as a pressure reducing valve and
controls the main valve (1).
The control pressure pSis transferred through
the control line (12) and acts on the operat-
ing diaphragm (6).
A drop in downstream pressure p2causes
the control pressure pSto rise. The force re-
sulting from the control pressure pSacting on
the operating diaphragm (6) overcomes the
forces created at the set point springs (7)
and the prevailing downstream pressure p2.
The main valve (1) opens.
A rise in downstream pressure p2causes the
control pressure pSto decrease. As a result,
the control pressure pSgradually reaches the
same level of the downstream pressure p2
causing the main valve (1) to be closed by
the set point springs (7).
Upon failure of the operating diaphragm (6),
the safety shut-off valve closes and the pres-
sure falls below the adjusted pressure set
point.
To ensure proper functioning of the regulator,
the minimum differential pressure Δpmin must
correspond to the pressure specied in Table
3-1.
Note

3-2 EB 2551-1 EN
Design and principle of operation
10
4
5
1
2
3
11
6
7
8.2
ps
p2
p
1
p2
p2
p1
12
ps8
8.1
8.3
9
1Main valve
2Seat
3Plug
4Plug stem
5Balancingbellows
6Operating diaphragm
7Set point springs
8Pilot valve
8.1 Filter
8.2 Restriction
8.3 Set point springs
9Set point adjuster
10 Control line for upstream pressure p1
11 Control line for downstream pressure p2
12 Control line for control pressure (pS)
Fig.3-1: Functional diagram

EB 2551-1 EN 3-3
Design and principle of operation
3.1 Additionalttings
ÎSeeFig.3-2
Strainers
We recommend installing a SAMSON
strainer (2) upstream of the regulator. It pre-
vents solid particles in the process medium
from damaging the regulator.
ÎDo not use the strainer to permanently
ltertheprocessmedium.
ÎSelectastrainer(meshsize)suitablefor
the process medium.
Any impurities carried along by the process
medium may impair the proper functioning
of the regulator. We recommend installing a
strainer (e.g. SAMSON Type2NI) upstream
of the pressure reducing valve (uEB1015).
Pressure gauges
Install a pressure gauge (3 and 5) both up-
stream and downstream of the regulator to
monitor the pressures prevailing in the plant.
Note
1 42 5 63
-
1Shut-off valve
2Strainer
3Upstream pressure gauge
4Safety shut-off valve (SSV)
5Downstream pressure gauge
6Shut-off valve
Fig.3-2: Sample application

3-4 EB 2551-1 EN
Design and principle of operation
Shut-off valves
We recommend installing a shut-off valve (1
and 6) both upstream of the strainer and
downstream of the regulator. The shut-off
valves ensure that the entire plant does not
need to be shut down for service and repair
work on the regulator.
Insulation
Regulators can be insulated to reduce heat
energy transfer.
Refer to the instructions in the 'Installation'
section.
3.2 Technical data
The regulator nameplate provides informa-
tion on the regulator version (see the 'Mark-
ings on the device' section).
More information is available in Data Sheet
uT2551-1.
Compliance
TheType33-1RegulatorbearsboththeCE
and EAC marks of conformity.
Leakage class
The soft-seated regulator has the leakage
classIVaccordingtoIEC60534-4.
Note
Type test
The device has been typetested as a safety
shut-offvalve(SSV)bytheGerman
Technical Inspectorate (TÜV) according to
therequirementsstipulatedintheAGFW
(GermanDistrictHeatingAssociation)
documentFW504.
The test mark is available on request.
Process medium and scope of application
TheType33-1SafetyShut-offValvewith
Pressure Reducing Valve is used to maintain
the pressure downstream of the valve to an
adjusted set point.
−Suitable for gases and liquids
−Max. temperature 150°C
−Set points from 1to10.5bar
−ValvesizeDN65to250
−Pressure ratings from PN16to40
The regulator is open when relieved of pres-
sure. The valve closes when the downstream
pressure rises.
Temperature range
Dependingonhowtheregulatoriscong-
ured, it can be used up to temperatures of
150°C(seeTable3-1).Theminimumtem-
perature is limited by the accessories used
and the actuator's diaphragm material
(uT2551-1).
Noise emission
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.

EB 2551-1 EN 3-5
Design and principle of operation
Table3-1: Technical data · All pressures in bar (gauge)
Valve size DN65 DN80 DN100 DN125 DN150 DN2002) DN2502)
Pressure rating PN16,25or40
Max. perm. temperature 150°C1)
Set point range (continuously
adjustable) 1to10.5bar
Minimum differential
pressureΔpmin 0.4bar 0.5bar 0.6bar
Max. perm. differential
pressure∆p 16bar 12bar 10bar
Max. permissible upstream
pressure p125bar
Compliance
1) Valvebodymadeofcastiron(EN-GJL-250),DN125to250:max.130°C,takingintoaccountthe
materialtableinDIN4747-1fortheuseoftheregulatorinhot-waterdistrictheatingnetworks.
2) DN200and250aswellassetpointrange1to16bar(nottypetested)availableonrequest.Itis
notpossibletotypetestvalvesinDN200and250sincethetestspecicationonlyappliesto
KVS380atthemaximum.However,theirdesignandfunctionareidenticaltothoseofthetypetested
valvesizes.
Table3-2: KVS coefcients and xFZ values · Terms for noise level calculation according to
VDMA 24422 (edition 1.89)
Valve size DN65 DN80 DN100 DN125 DN150 DN200 DN250
KVS coefcient 50 80 125 190 280 420 500
Value at KVS 0.31) 1.6 1.7 2.0 2.4 3.0 5.0
xFZ value 0.40 0.35 0.30
1) Despite installing a strainer upstream of the regulator, dirt particles may impair the valve shut-off
dependingonthesizeofthestrainermesh.OnusingtheSAMSONType2NIStrainer,the
maximumleakageratemaycorrespondtothespeciedvalueatKVS0.3duetothecloggingupof
thevalve.Thisvalueisthensignicantonsizingthesafetyvalveorsafetyexcesspressurevalvein
the plant.
Dimensions and weights
Table 3-4 provides a summary of the dimen-
sions and weights. The lengths and heights
in the dimensional drawing are shown on
page3-7.

3-6 EB 2551-1 EN
Design and principle of operation
Table3-3: Materials · Material numbers according to DIN EN
Valve
Pressure rating PN16 PN16·PN25 PN16·PN25·PN40
Body Cast iron
EN-GJL-250
Spheroidal graphite iron
EN-GJS-400-18-LT1)
Cast steel
1.0619
Seat Stainless steel 1.4006
Plug with EPDM
seal
DN65to100 Stainless steel 1.4006
DN125to250 Stainless steel 1.4301
Balancingbellows Stainless steel 1.4571
Seal Graphiteonmetalcore
Actuator
Diaphragm cases Sheet steel DD11 (StW22)
Diaphragm EPDM with fabric reinforcement
Guidebushing DU bushing with EPDM seal
Pilot valve
Body BrassCW600N/1.4541
Plug BrassCW617N
Metal bellows BrassCW502L
Control lines Steel, special version: copper
Screwttings Steel
1) DN150andsmaller
Table3-4: Dimensions in mm and weights in kg
Valve size DN65 DN80 DN100 DN125 DN150 DN200 DN250
Length L 290 310 350 400 480 600 730
Height H1) 335 390 510
Height H2 100 120 145 175 235 260
Actuator area A=640cm²
Diaphragm housing ØD=380mm
Weight(approx.)forPN162) 53kg 58kg 66kg 96kg 140kg 280kg 330kg
1) +15mmforPN40
2) +10%forcaststeel1.0619andspheroidalgraphiteironEN-GJS-400-18-LT

EB 2551-1 EN 3-7
Design and principle of operation
Dimensional drawings
L
H
ØD
H2
Fig.3-3: Dimensions

3-8 EB 2551-1 EN
Design and principle of operation