Samson 41-73 Series Service manual

Mounting and

Operating Instructions

EB 2517 EN

Edition July 2015

Self-operated Pressure Regulators

Type41-73 Universal Excess Pressure Valve

Type 41-73 Excess Pressure Valve

Denition of signal words

DANGER!

Hazardous situations which, if not

avoided, will result in death or seri-

ous injury

WARNING!

Hazardous situations which, if not

avoided, could result in death or seri-

ous injury

NOTICE

Property damage message or mal-

function

Note:

Additional information

Tip:

Recommended action



2 EB 2517 EN

Contents

EB 2517 EN 3

1 General safety instructions .............................................................................4

2 Process medium and scope of application .......................................................5

2.1 Transportation and storage.............................................................................5

3 Design and principle of operation ..................................................................5

4 Installation ....................................................................................................6

4.1 Assembly ......................................................................................................6

4.2 Mounting position..........................................................................................8

4.3 Control line, compensation chamber and needle valve......................................9

4.4 Strainer(lter)..............................................................................................10

4.5 Shut-off valve...............................................................................................11

4.6 Pressure gauge ............................................................................................11

5 Operation ...................................................................................................12

5.1 Start-up.......................................................................................................12

5.2 Adjusting the set point..................................................................................12

5.3 Decommissioning.........................................................................................13

6 Cleaning and maintenance ..........................................................................14

6.1 Replacing the operating diaphragm ..............................................................14

7 Nameplate ..................................................................................................16

8 Dimensions .................................................................................................17

9 Customer inquiries ......................................................................................18

10 Technical data .............................................................................................19

4 EB 2517 EN

General safety instructions

1 General safety instructions

−The regulator is to be mounted, started up or serviced by fully trained and

qualiedpersonnelonly;theacceptedindustrycodesandpracticesareto

be observed. Make sure employees or third persons are not exposed to any

danger.

−All safety instructions and warnings given in these mounting and operating

instructions, particularly those concerning installation, start-up and mainte-

nance, must be strictly 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 dangers due to their specialized training, their

knowledge and experience as well as their knowledge of the applicable

standards.

−The regulators comply with the requirements of the European Pressure Equip-

ment Directive 2014/68/EU. Devices with a CE marking have a declaration

of conformity, which includes information about the applied conformity as-

sessment procedure.This declaration of conformity can be provided on re-

quest.

−To ensure appropriate use, only use the regulator in applications where the

operatingpressureandtemperaturesdonotexceedthespecicationsused

for sizing the regulator at the ordering stage.

−The manufacturer does not assume any responsibility for damage caused by

external forces or any other external factors.

−Any hazards that could be caused in the regulator by the process medium,

operating pressure or by moving parts are to be prevented by taking appro-

priate precautions.

−Proper transport, storage, installation, operation and maintenance are as-

sumed.

EB 2517 EN 5

Process medium and scope of application

2 Process medium and scope of application

Pressure regulators for set points from 0.05 to 28bar · Valve nominal sizes DN15 to 100

Nominal pressure PN16 to 40 · Suitable for liquids, gases and vapors up to 350°C

The valve opens when the upstream pressure rises.

NOTICE

The Type41-73 Excess Pressure Valve is not a safety valve. If necessary, a suitable

overpressure protection must be installed on site in the plant section.

2.1 Transportation and storage

The regulator must be carefully handled, transported and stored. Protect the regulator against

adverseinuences,suchasdirt,moistureorfrostbeforeitisinstalled.

When regulators are too heavy to be lifted by hand, fasten the lifting sling at a suitable place

on the valve body.

NOTICE

Do not attach any lifting equipment, slings or supports to mounting parts, such as the

adjusting screw or control line.

3 Design and principle of operation

See Fig.1 on page7.

TheType41-73ExcessPressureValveconsistsofaType2417OpeningValveanda

Type2413Actuator.Thevalveandactuatoraredeliveredseparatelyandmustbeassembled

accordingtotheinstructionsinsection4.1.

The excess pressure valve is used to maintain the pressure upstream of the valve to an adjust-

ed set point.

Theprocessmediumowsthroughthevalvebetweenseat(2)andplug(3)inthedirectionin-

dicatedbythearrowonthebody.Thepositionofthevalveplugdeterminestheowrate

and the pressure ratio across the valve. The plug stem is sealed by a frictionless bellows

6 EB 2517 EN

Installation

(5.1).Theupstreampressurep1is transmit-

tedthroughthecompensationchamber(18)

andcontrolline(17)totheoperatingdia-

phragm(12)whereitisconvertedintoapo-

sitioning force. For actuator versions with a

bellows, the pressure is transmitted to the op-

eratingbellows(12.1).Thepositioningforce

is used to move the valve plug according to

theforceofthepositioningsprings(7).The

spring force is adjustable at the set point ad-

juster(6).ValveswithKVS4 and higher fea-

tureabalancingbellows(4).Theupstream

pressure acts on the outside of the bellows

and the downstream pressure on the inside

of the bellows. As a result, the forces pro-

duced by the upstream and downstream

pressures acting on the plug are balanced.

Depending on the valve and actuator used,

the regulator can be upgraded to create a

safety excess pressure valve.

4 Installation

4.1 Assembly

See Fig.1 on page7.

Valve and actuator can be assembled before

or after the valve has been installed in the

pipeline.

Pushthediaphragmactuator(10)withactu-

atorstem(11)throughtheholeinthecross-

beam(8)ontothespigotsofthebellows

(5.1).Alignitandfastenwithnuts(width

acrossats16,9)ontothevalveange(ap-

prox.25Nm).

For metal bellows actuators in DN15 to 50,

removethecrossbeam(8)fromthevalve.

Pushtheactuatorstem(11)ontothespigots

ofthebellows(5.1).Alignthepillars(8.1)

andfastenwithnuts(widthacrossats24,

8.2)totheactuator(max.60Nm).

For metal bellows actuators in DN65 to

100,removethecrossbeam(8)fromthe

valveandunscrewthepillars(8.1).Screw

thepillarsintothethreadedholes(8.3)ofthe

actuatorangeasfarastheywillgo.Push

theactuatorwithactuatorstem(11)ontothe

spigotsofthebellows(5.1).Fastenthepillars

withnuts(widthacrossats24,8.2)ontothe

valveange(max.60Nm).

1 Valve body

2 Seat

3 Plug

4 Balancing bellows

5 Plug stem

5.1 Bellows

6 Set point adjuster

7 Set point springs

8 Bracket

8.1 Pillar

8.2 Nuts for pillars

8.3 Tapped holes

9 Fastening nuts

10 Diaphragm actuator

11 Actuator stem

12 Operatingdiaphragm

12.1Operatingbellows

13 Diaphragm plate

14 Nut

15 Nuts and bolts

16 Control line connection G ¼ (for steam including

screwjointwithrestriction)

17 Control line installed on site (control line kit available

for tapping the pressure directly at the valve body,

seeT2595)

18 Compensation chamber

19 Filler plug

EB 2517 EN 7

Installation

5.1

18 19 p1p2

8.2

8.1

8.2

12.1

8.2

8.3

Fig.1: Functional diagram

ActuatorforDN65to100

Type2413Actuatorwithmetalbellowsfor2to6bar,5to10bar,10to22barand20to28bar

DN15to50

Type 2417 Valve

Type2413 Diaphragm

Actuator

Pillars turned by

90° in the

drawing

Type41-73Regulator·DN32to100·Withbalancingbellows

8 EB 2517 EN

Installation

4.2 Mounting position

NOTICE

Protect the regulator from icing up

when controlling media that can

freeze. Remove the regulator from

the pipeline when the plant is shut

down if the regulator is not installed

areas free from frost.

Flush the pipeline thoroughly before install-

ing the regulator to ensure that any sealing

parts, weld spatter and other impurities car-

ried along by the process medium do not im-

pair the proper functioning of the valve,

above all the tight shut-off.

NOTICE

Install a strainer (e.g. SAMSON

Type2) upstream of the regulator.

Install the excess pressure valve in horizontal

pipelines.Oninstallingthevalve,makesure

thedirectionofowcorrespondswiththear-

row on the body. For media with a tendency

to condensate, install the pipeline with a

slight downward slope on both sides so that

the condensate can drain properly. If the

pipeline upstream and downstream of the

valve run vertically upwards, an automatic

waterdrainage(e.g.SAMSONType13E

SteamTrap)isrequired.Chooseaplaceof

installation that allows you to freely access

the regulator even after the entire plant has

been completed. The regulator must be in-

stalled free of stress. If necessary, support

thepipeneartheconnectinganges.

Standard mounting position

For gases, liquids and steam

Alternative mounting position

For Gases and liquids at medi-

um temperature up to 80°C

Not for steam

Notpermissible1)

1) Installation in this position on

request

Fig.2: Mounting position

NOTICE

Do not attach supports directly to the

valve or actuator.

If a bypass line is to be used, it must be con-

nected upstream of the pressure tapping

point. Install a shut-off valve in the bypass

line.

Note:

Do not install any instruments (e.g.

temperature regulators or shut-off

valves) that restrict the cross-section

of the pipe between the pressure tap-

ping point and the valve.



EB 2517 EN 9

Installation

4.3 Control line, compensation

chamber and needle valve

Control line · A control line must be provid-

ed at the site of installation, e.g. a

“ pipe

forsteamoran8x1or6x1mmpipefor

air/water.

Connect the control line to the upstream line

(p1)atleastonemeterawayfromthevalve

inlet.

Weld the control line at the side in the mid-

dle of the pipe, inclining at a ratio of ap-

proximately 1:10 up to the compensation

chamber.

Control line kit · A control line kit for tap-

ping pressure directly at the valve body is

available as an accessories part from SAM-

SON.

Compensation chamber(seeTable1)·A

compensation chamber is required for liq-

uidsabove150°Caswellasforsteam.The

mounting position of the compensation

chamber is indicated by an adhesive label

on the chamber itself as well as by an arrow

and the word "top" stamped on the top of

the chamber.

Fig.3: Example of installation with steam

Table1: Assignment of compensation chamber (4) to

regulator

Type2413 Actuator

Actuator area A

Item no.∙Compensation chamber

DN15 to 50 DN65 to 250

640cm² 1190-8789 1190-8790

320cm² 1190-8788 1190-8789

160,80,40cm² 1190-8788

1 Shut-off valve

2 Upstream pressure gauge

3 Strainer

4 Compensation chamber

5 Excess pressure valve

6 Downstream pressure gauge

7 Shut-off valve

1234567

10 EB 2517 EN

Installation

Thismountingpositionmustbeadheredto;

otherwise the safe functioning of the excess

pressure valve cannot be guaranteed.

Weld the line coming from the pressure tap-

ping point to the

“ pipe socket on the

chamber. Install the compensation chamber

at the highest point of the pipeline. Conse-

quently, the control line between compensa-

tion chamber and actuator must also be in-

stalled with a downward slope. In this case,

use a

“pipewithscrewttings.

If the control line connection is located below

themiddleofthevalveinletange,arrange

the compensation chamber at the same level

astheinletange.Inthiscase,useapipe

which is at least ½“ in size for the control

line from the tapping point to the compensa-

tion chamber.

If the control line is connected above the

middleofthevalveoutletange,installthe

compensation chamber at the same level as

the upstream pressure tapping point. The ad-

ditional pressure of the condensate head

must be compensated for by adjusting the set

point.

Needle valve · If the regulator tends to hunt,

we recommend installing a needle valve at

thecontrollineconnection(16)inadditionto

thestandardSAMSONscrewjointwithre-

striction.

4.4 Strainer (lter)

Install the strainer upstream of the excess

pressurevalve.Thedirectionofowmust

correspondtothearrowonthebody.Thel-

ter element must be installed to hang down-

wards or sideways for applications with

steam. Remember to leave enough space to

removethelterelement.

4.5 Shut-off valve

Install a hand-operated shut-off valve both

upstream of the strainer and downstream of

the regulator. This allows the plant to be shut

down for cleaning and maintenance, and

when the plant is not used for longer periods

of time.

4.6 Pressure gauge

Install a pressure gauge both upstream and

downstream of the regulator to monitor the

pressures prevailing in the plant. Install the

pressure gauge on the upstream side in front

of the upstream pressure tapping point (not

betweenthetappingpointandthevalve).

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