Samson 46-7 Service manual

Translation of original instructions
EB 3131-1 EN
Type46-7 Flow and Differential Pressure Regulator with additional
pressure control actuator
Self-operated Regulators
Edition December 2020

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
([e-mail]).
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.samsongroup.com > 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 3131-1 EN

Contents
EB 3131-1 EN 3
1 Safety instructions and measures ...................................................................4
1.1 Notes on possible severe personal injury .........................................................6
1.2 Notes on possible personal injury ...................................................................7
1.3 Notes on possible property damage................................................................8
2 Markings on the device .................................................................................9
3 Design and principle of operation ................................................................10
3.1 Technical data .............................................................................................13
4 Measures for preparation............................................................................17
4.1 Unpacking ..................................................................................................17
4.2 Transporting and lifting ................................................................................17
4.3 Storage.......................................................................................................17
5 Mounting and start-up.................................................................................18
5.1 Mounting orientation....................................................................................18
4.4 Preparation for installation............................................................................18
5.2 Additionalttings.........................................................................................20
5.3 Putting the regulator into operation................................................................20
6 Operation...................................................................................................22
6.1 Adjusting the set points.................................................................................22
6.1.1 Flow control.................................................................................................22
6.1.2 Differential pressure control...........................................................................25
6.1.3 Pressure control............................................................................................27
6.2 Pressure measurement at the regulator...........................................................28
7 Servicing.....................................................................................................29
7.1 Preparation for return shipment.....................................................................29
7.2 Ordering spare parts and operating supplies .................................................29
8 Malfunctions ...............................................................................................30
9 Decommissioning and removal ....................................................................32
9.1 Decommissioning.........................................................................................32
9.2 Disposal......................................................................................................32
10 Annex.........................................................................................................33
10.1 After-sales service........................................................................................33
10.2 Certicates ..................................................................................................33

4 EB 3131-1 EN
Safety instructions and measures
1 Safety instructions and measures
Intended use
TheType46-7FlowandDifferentialPressureRegulatorwithadditionalpressurecontrolactu-
atorisdesignedfortheowrateanddifferentialpressurecontrolofliquidsupto150°C.
Theadditionalpressurecontrolactuatorclosesthevalvewhenthereturnowpressureistoo
high.TheType46-7ismainlyusedindistrictheatingsupplynetworksandindustrialplants.
Theregulatorandactuatoraredesignedtooperateunderexactlydenedconditions(e.g.
operating pressure, process medium, temperature). Therefore, operators must ensure that the
regulatorandactuator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 devices
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 regulator is not suitable for the following applications:
−Useoutsidethelimitsdenedduringsizingandbythetechnicaldata
Furthermore, the following activities do not comply with the intended use:
−Use of non-original spare parts
−Performing service and repair work not described
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.

EB 3131-1 EN 5
Safety instructions and measures
Personal protective equipment
We recommend wearing the following protective equipment depending on the process medi-
um:
ÎProtective clothing, safety gloves and eye protection in applications with hot, cold and/or
corrosive media
ÎWear 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 or by moving parts by taking appropriate precautions. Plant operators and operat-
ing personnel must observe all hazard statements, warning and caution notes in these
mounting and operating instructions, especially for installation, start-up and service work.
Responsibilities of the operator
Operators are responsible for proper use and compliance with the safety regulations. Opera-
tors are obliged to provide these mounting and operating instructions as well as the refer-
enced documents to the operating personnel and to instruct them in proper operation. Fur-
thermore, operators must ensure that operating personnel or third parties are not exposed 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, operating personnel must be familiar with the applicable
health, safety and accident prevention regulations and comply with them.

6 EB 3131-1 EN
Safety instructions and measures
Referenced standards, directives and regulations
The regulators comply with the requirements of the European Pressure Equipment Directive
2014/68/EU. Devices with a CE marking have a declaration of conformity, which includes
information about the applied conformity assessment procedure. This declaration of confor-
mityisincludedintheannexoftheseinstructions(seesection10.2).
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:2009,section5.2,evenintherareincidentofanoperatingfault.Therefore,
such valve versions 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0165-1).
1.1 Notes on possible severe personal injury
DANGER
!
Risk of bursting in pressure equipment.
Valvesandpipelinesarepressureequipment.Improperopeningcanleadtodevice
components bursting.
ÎBefore starting any work on the device, depressurize all plant sections affected as
well as the valve.
ÎDrain the process medium from all the plant sections affected as well as the valve.
ÎIf necessary, a suitable overpressure protection must be installed on site in the plant
section.
ÎWear personal protective equipment.

EB 3131-1 EN 7
Safety instructions and measures
1.2 Notes on possible personal injury
WARNING
!
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 valve.
Whileworkingonthevalve,residualmediumcanowoutofthevalveand,depending
on its properties, cause personal injury, e.g. (chemical) burns.
ÎIf possible, drain the process medium from all the plant sections affected and the
valve.
ÎWear protective clothing, safety gloves and eye protection.
Risk of burn injuries due to hot or cold components and pipelines.
Depending on the process medium, valve 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 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 uwww.samsongroup.com/en/
about-samson/material-compliance/reach-regulation/.

8 EB 3131-1 EN
Safety instructions and measures
1.3 Notes on possible property damage
NOTICE
!
Risk of valve 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 valve and plant.
Risk of valve damage due to unsuitable medium properties.
Thevalveisdesignedforprocessmediawithdenedproperties.
ÎOnlyuseprocessmediaspeciedforsizingthevalve.

EB 3131-1 EN 9
Markings on the device
2 Markings on the device
1
23
45
6
7
8
9
10
NameplateofType46-7
1CongurationID
2 Model number
3 Date of manufacture
4 KVS/CV
5 Pressure rating PN or Class
6Differential pressure set point range in bar or
psi
7 Type designation
8 Flow rate set point range in m³/h or gal/min
9Maximumpermissibletemperaturein°Cor°F
10 Max.permissibledifferentialpressure∆pin
bar or psi
1
Nameplate on the pressure control
actuator
1 Set point range (pressure) in bar or psi

10 EB 3131-1 EN
Design and principle of operation
3 Design and principle of oper-
ation
The combined regulators mainly consist of
the valve (1), closing actuator (6) with two
operating diaphragms (6.1, 6.3) and an ad-
justable restriction (9), on which an addition-
al pressure control actuator (15) with dia-
phragm chamber E is mounted. Its purpose
is to close the restriction (9) when the return
owpressureistoohightopreventdamage
to the consumers.
The regulator is used to limit the differential
pressureandowratetothesetpointsad-
justed at the actuator. The valve closes when
thedifferentialpressureorowrateincreas-
es. The additional pressure actuator closes
thevalvewhenthereturnowpressureistoo
high.
Themediumowsthroughthevalveinthe
direction indicated by the arrow. The areas
released by the restriction (9) and the plug
(3)determinetheowrate.Theinstalled
spring (5) determines the differential pres-
sureacrosstherestrictionof0.2bar.
Tocontroltheowrate,thelowpressure
downstream of the restriction is transmitted
through a hole in the plug to the top dia-
phragm chamber A. The high pressure of V
is transmitted through the attached control
line to the diaphragm chamber B and C,
which are connected to each other.
To control the differential pressure, the high
pressureof∆pmustbetransmittedthrough
the external control line (13), which is at-
tached on the site of installation, to the bot-
tom diaphragm chamber D. The low pres-
sureof∆pisequaltothehighpressureof
the Vandistransmittedoverthecontrolline
(11) to the diaphragm chambers B and C,
which are connected to each other.
Tosafeguardthereturnowpipe,thereturn
owpressuredownstreamofthevalveis
transmitted over the attached control line
(15.2) to diaphragm chamber E of the addi-
tional pressure control actuator (15) and
compared with the adjusted pressure set
point. If the resulting pressure force is higher
than the set point force adjusted at the set
point adjuster (15.1), the restriction closes,
causing the valve to close as well.
˙
˙
1Valvebody
2 Seat
3 Guide nipple with plug section
4 Plug stem
5Valvespring
6 Actuator
6.1 First operating diaphragm
6.2 First actuator stem
6.3 Second operating diaphragm
6.4 Second actuator stem
8 Set point spring (differential pressure)
9Restriction(owrate)
9.1 Setpointscrew(owrate,SW4)
10 Set point adjuster (differential pressure)
11 Control line (+) V
13 Externalcontrolline(+)Δp
15 Pressure control actuator
15.1 Set point adjuster (pressure)
15.2 Control line (pressure)
15.3 G
1
/
8
blanking plug
15.4 Set point spring (pressure)
AtoE=Diaphragmchambers
˙

EB 3131-1 EN 11
Design and principle of operation
1
15.2
15.1
15
15.2
9.1
9
3
4
5
11
13
6
8
10
6.2
A
B
C
D
6.4
6.3
11
11
6.1
V
15.3
p1
p
2
Δp
•
2
15.4
E
Fig.1: Flow and differential pressure regulator with additional pressure control actuator · DN15
and 25

12 EB 3131-1 EN
Design and principle of operation
9.2
8
10
9
9.3
8Set point spring
(differential pressure)
9Restriction
9.2 Knurled
nut(flowrate,SW5)
9.3 Nipple with retaining
screw and lead-seal hole
10 Set point adjuster
(differential pressure)
Fig.2: Flow and differential pressure regulator with additional pressure control actuator · DN40

EB 3131-1 EN 13
Design and principle of operation
3.1 Technical data
Process medium and scope of application
Flow rate and differential pressure control
with pressure control in district heating sup-
plynetworksandindustrialplants·Valves
DN15,25and40·PressureratingPN16
and25·Suitableforliquidsupto150°C
Thevalvecloseswhentheowrate,differen-
tial pressure or pressure rises.
Regulatorforinstallationinthelow-pressure
pipe,e.g.plantreturnowpipeofadistrict
heating substation.
Min. differential pressure Δpmin
The minimum required differential pressure
Δpmin across the valve is calculated as fol-
lows:
Δpmin = Δprestriction +
(
V
)
2
KVS
·
Δpmin Minimum differential pressure across the valve in bar
Δprestriction Differentialpressurecreatedattherestrictionformeasuringtheowrate
V
·Adjustedowrateinm³/h
KVS Valveowcoefcientinm³/h
Dimensions and weights
The lengths and heights in the dimensional
drawingsareshownonpages15and
16.
Dimensions in mm · Weights in kg
The dimensions and weights of valves with
anged bodies (DN40) are the same as
valves with screwed-on anges.
Note

14 EB 3131-1 EN
Design and principle of operation
Table1: Technical data
Valve size DN15 DN25 DN40
KVScoefcient 4 8 16
xFZ value 0.6 0.55 0.55
Pressure rating PN16/25 PN16/25 PN 25
Max. permissible differential
pressure∆pacrossthevalve
PN16 10bar 10bar –
PN 25 20bar 20bar 16bar
Max. permissible temperature PN16 130°C 130°C –
PN 25 150°C 150°C 150°C
Pressure above adjusted differential pressure set
point at which internal excess pressure limiter
responds
0.5bar
Conformity
Pressure set point ranges
Pressure set point, continuously adjustable 1to2.5bar
Differential pressure set point ranges
Differential pressure set point, continuously
adjustable
0.2to0.6bar
0.2to1.0bar
0.5to2bar
0.2to0.5bar
0.2to1.0bar
0.5to2bar
Table2: Regulator without connecting parts
Valve size DN15 DN25 DN40
Pipe Ø d 21.3 32.7 48
ConnectionR G¾ G1¼ G2
Widthacrossats
SW 30 46 65
Length L 65 75 110
H62 62 110
H1 185 185 420
H4 214 214 214
ØD1 116 160
ØD2 116(40cm²actuator)

EB 3131-1 EN 15
Design and principle of operation
Dimensional drawings
DN15and25
DN40
ØD1
H4H1 H
L
ØD2
L1
d
R
ØD1
H4H
H1
L
ØD2

16 EB 3131-1 EN
Design and principle of operation
Table3: Regulator with connecting parts
Valve size DN15 DN25 DN40
With welding ends
L1 210 244 294
Weight, approx.
kg
2.6 2.8 12
2.2 2.4 6.2
With threaded ends
L2 129 159 206
Male thread A G½ G1 G1½
Weight, approx.
kg
2.6 2.8 12
2.2 2.4 6.2
With anges 1) 2) or with anged body (DN40)
L3 130 160 200
Weight, approx.
kg
4.0 5.3 16.0
3.6 4.9 10.2
1) PN16/25
2) FlangesarealreadymountedonvalvesinDN40.
Dimensional drawings
SW
L
L3
A
SW
L
L2
Connectionnutswithanges Connection nuts with threaded ends

EB 3131-1 EN 17
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).
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 stor-
age conditions or longer storage times.
We recommend regularly checking the de-
vice 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.
Note
NOTICE
!
Note

18 EB 3131-1 EN
Measures for preparation
Special storage instructions for elastomers
Elastomer, e.g. actuator 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.
4.4 Preparation for installation
Proceed as follows:
ÎFlush the pipelines.
The plant operator is responsible for clean-
ing the pipelines in the plant.
ÎCheck the valve to make sure that it is
clean.
ÎCheck the valve for damage.
ÎCheck to make sure that the type desig-
nation, valve size, material, pressure rat-
ing and temperature range of the valve
match the plant conditions (size and
pressure rating of the pipeline, medium
temperature etc.).
ÎCheck any mounted pressure gauges to
make sure they function.
Tip
Note
5 Mounting and start-up
5.1 Mounting orientation
Standard mounting position
ÎInstall the regulator in a horizontal pipe-
line with the set point adjuster (10) fac-
ingdownward(seeFig.1andFig.2).
Installation conditions
−Make sure that the regulator remains
freely accessible after the plant has been
completed.
−Install a strainer upstream of the regula-
tor(seesection5.2).
−Thedirectionofowmustmatchthedi-
rection indicated by the arrow on the
body.
−Connect external control lines at the side
ofthemainpipe(seeFig.5)
−Install the regulator free of stress.
Possible malfunction and damage due to ad-
verse weather conditions (temperature, hu-
midity).
−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.
NOTICE
!

EB 3131-1 EN 19
Mounting and start-up
V
Δp
•
–
+
+
–
M
Fig.3: Installation example
MDN
min.
b x DN
min.
3 x DN
min.
3 x DN
min.
a x DN
Control
line
State of process medium Valve conditions Inlet length a Outlet length b
Liquid w<2
m
/
s
2 4
Fig.4: Control line connection and how the pipeline is routed
Pipeline routing
The inlet and outlet lengths vary depending
on several variables and process conditions
and are intended as recommendations. Con-
tactSAMSONifthelengthsaresignicantly
shorter than the recommended lengths.
To ensure that the regulator functions proper-
ly, proceed as follows:
ÎObserve the inlet and outlet lengths (see
Fig.4).ContactSAMSONiftheregula-
tor conditions or state of the medium
process deviate.

20 EB 3131-1 EN
Mounting and start-up
5.2 Additional ttings
Strainer
Astrainerinstalledupstreamintheowpipe
holds back any dirt or other foreign particles
carried along by the medium. For example,
theSAMSONType1NIStrainerissuitable
(uT1010).
−Install the strainer upstream of the regu-
lator.
−Thedirectionofowmustcorrespondto
the arrow on the valve body.
−Thelterelementmustbeinstalledto
hang downward.
−Allowsufcientspacetoremovethelter.
Shut-off valve
Install a hand-operated shut-off valve both
upstream of the strainer and at the outlet of
thereturnowpipe(seeFig.3).Thisallows
the plant to be shut down for cleaning and
maintenance, and when the plant is not used
for longer periods of time.
Pressure gauge
Install a pressure gauge at a suitable point to
monitor the pressures prevailing in the plant
(seeFig.3).
Control line
Depending on the regulator version, a con-
trolline(standard:6x1mmpipediameter)
must be adapted and mounted on site. Make
sure that the control line is free of dirt.
We recommend installing the control line for
tapping pressure from the pipeline at a dis-
tance of at least three times the valve size
(DN)awayfromanypipettings(e.g.mani-
folds, bends, branches or other valves), that
maycauseturbulenceintheow.
Howthelinesareroutedgenerallydepends
on the installation site. Preferably connect the
control line to the side of the main pipe.
ÎDo not change the pipe diameter of the
main pipeline with an eccentric reducer.
ÎRefertoinstallationschematics(Fig.3)
for line routing.
5.3 Putting the regulator into
operation
ÎDo not start up the regulator until all
parts have been mounted.
ÎMake sure the control lines are open and
correctly connected.
ÎMake sure that the restriction (9) is open
whilellingtheplant.Toopenit,turnthe
set point adjuster of the pressure control
actuator (15.1) counterclockwise () (see
section6.1.3).
ÎOpen the shut-off valves slowly over a
time period of several minutes starting
from the upstream pressure side. After-
wards, open all the valves on the con-
sumer side (downstream of the regula-
tor).