Mounting and Operating Instructions EB 2723 EN
Contents
1. in EN 60079 14 1977 VDE 0165 Part 1 section 6 3 2 amp B 2723 EN General safety instructions General safety instructions The excess pressure valve must be installed started up and serviced only by skilled or semi skilled staff in accordance with good engineering practice so that employees and third persons are not exposed to 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 The valve complies with the requirements of the European Pressure Equipment Directive 97 23 EC The declaration of conformity issued for a valve bearing the CE marking includes information on the applied conformity assessment procedure and will be provided on request To ensure appropriate use only use the valve in applications where the operating pressure and temperatures do not exceed the operating values specified in the order Note that the manufacturer does not assume any responsibility for damage caused by external forces or any other external factors Take appropriate safety precautions to prevent hazards that may be caused in the valve by the process medium operating pressure or moving parts Make sure the valve is shipped and stored properly EB 2723EN 3 Design and principle of operation 1 Design and principle of operation The excess pressure valve is typically used in district heating2. plants and large heating sys tems to maintain a constant desired upstream pressure Increasing upstream pressure will cause the valve to open The Type 44 7 and Type 44 8 Excess Pres sure Valves consist of a valve body with a balanced valve plug and an actuator with an operating diaphragm and a spring assembly The Type 44 8 is designed as a safety ex cess pressure valve SEV It incorporates a second diaphragm to ensure continued safe operation of the valve even upon failure of the operating diaphragm If the upstream pressure exceeds a specified high value the safety excess pressure valve will fail open Table 1 Tightening torques Observe the tightening torques listed below when assembling the valve upon replacement of the plug or the diaphragm Description Nominal size DN 15 to 25 Body stopper DN 32 to 50 DN 15 to 32 Body screws DN 40 to 50 DN 15 to 25 en DN 40 to 50 DN 15 to 25 Diaphragm plate nut DN 15 to 50 Control line connection DN 15 to 50 4 EB2723 EN The medium flows through the valve in the di rection indicated by the arrow on the valve body The upstream excess pressure to be controlled passes through the control line 11 and flows into the area above the oper ating diaphragm 6 1 It acts on the operat ing diaphragm producing a positioning force This force is used to position the valve plug against the force of the spring
3. 723 EN S Z 2011 10 Conversion from chromate coating to iridescent passivation D Conversion from chromate coating to iridescent passivation We at SAMSON are converting the surface treatment of passivated steel parts in our production As a result you may receive a device assembled from parts that have be en subjected to different surface treatment methods This means that the surfaces of so me parts show different reflections Parts can have an iridescent yellow or silver color This has no effect on corrosion protection For further information go to www samson de chrome en html
4. Diaphragm plate O ring EB2723EN 5 Installation 2 Installation 2 1 Mounting position Install the valve in a horizontal pipeline with the actuator and spring assembly suspended downwards Make sure that the medium flows through the valve in the direction indicated by the arrow on the valve body Use the connection nuts included in the delivery to install the valve 2 2 Strainer Note Do not connect a strainer upstream of the Type 44 8 SEV Install a strainer e g SAMSON Type 1 NI upstream of the Type 44 7 Valve to prevent sealing particles weld spatter and other im purities carried along by the process medium from impairing the proper operation espe cially the tight shut off of the valve Hand operated shut off valve Upstream pressure gauge Strainer for Type 44 7 only Excess pressure valve Downstream pressure gauge C1 amp Co l0 Fig 3 Installation example 6 EB2723 EN Make sure that the medium flow corresponds with the direction indicated by the arrow on the strainer body Install the strainer with the filter element suspended downwards Ensure that enough space is available to remove the ilter 2 3 Additional installation instructions Ideally hand operated shut off valves should be installed both upstream of the strainer and downstream of the excess pressure valve They allow the pipeline section to be shut down for cleaning and maintenance routines or when i
5. Excess Pressure Valves Type 44 7 and Type 44 8 SEV Fig 1 Type 44 7 Excess Pressure Valve DN 40 Mounting and Operating Instructions CE EB 2723 EN Edition September 2007 Contents Contents Page 1 Design and principle of operation 22 2 2222 A 2 Installation 22222 Co oo oo 6 2 1 Mounting position 22 2 ll ses 6 2 2 Ae 4 a M NE RNC E E E DR C C CREDO EE Oe SEE Bw 6 2 3 Additional installation instructions 22 2222 2 222 6 3 Operation ues a wee eka 59250 4 4 S 3 wa eee hes 6 3 1 sik p cT 6 3 2 Set point adjustment 2 nn 7 3 9 OluEdow e qos E owe ee Kr anes 7 4 Maintenance lll sls ses 7 4 1 Cleaning or replacing the plug 2 2222 2 lll 7 4 2 Replacing the diaphragm 2 2 2 2 2 2 mn nn 8 5 Nameplate 22222 oo oo onen 9 6 Customer inquiries aaa ee 9 7 Dimensions and weights a aaa a 10 Note These Mounting and Operating Instructions EB 2723 EN refer to the Type 44 7 and Type 44 8 Excess Pressure Valves manufactured from August 2005 onwards 0085 see nameplate Note Non electric actuators and control valve versions do not have their own potential ignition source according to the ignition risk assessment stipulated in EN 13463 1 2001 section 5 2 even in the rare incident of an operating fault Therefore they do not fall within the scope of Directive 94 9 EC For connection to the equipotential bonding system observe the requirements specified
6. Has a strainer been installed Installation drawing with exact location of the regulator and all additional installed components shut off valves pressure gauge etc EB2723EN 9 Dimensions and weights 7 Dimensions and weights Dimensions in mm and weights in kg Standard version with connection nuts with welding ends Nominal size DN 15 20 25 32 40 50 Pipe diameter d 21 9 26 8 dd 42 48 60 Connection R G 54 G 1 G 114 G 1 G2 G 2 Width across flats SW 30 36 46 59 65 82 Length L 65 70 75 100 110 130 L1 with welding ends 210 234 244 268 294 330 l l Type 44 7 230 250 380 i Type 44 8 235 255 395 Type 44 7 Dimension H1 A 58 Type 44 8 Weight approx in kg 2 0 2 1 2 2 ke 9 0 70 Version with flanged body DN 32 40 50 Length L3 130 150 160 180 200 Weight approx in kg 3 5 4 1 4 7 1157 13 Special version with threaded ends male thread Length L2 129 144 159 180 196 228 Male thread A GY G G1 G 114 G1 G2 Weight approx in kg 2 0 2 1 2 2 8 5 9 0 va 10 EB 2723 EN Dimensions and weights Dimensions With connection nuts with threaded ends Flanged body DN 32 to 50 only Fig 5 Dimensional drawings EB2723EN 11 SAMSON AG MESS UND REGELTECHNIK Weism llerstraBe 3 60314 Frankfurt am Main Germany Phone 49 69 4009 0 Fax 49 69 4009 1507 Internet http www samson de EB 2
7. Prior to carrying out any work al ways depressurize the relevant sec tion and drain it depending on the medium First allow the relevant section of the plant to cool down to ambient tem perature if high temperatures prevail We recommend that the valve be re moved from the pipeline for carrying out any work on the valve When controlling freezing media protect the regulator against frost Maintenance If the upstream pressure drops considerably tight shut off is impaired by dirt between the seat and plug or due to natural wear For Type 44 8 SEV two diaphragms only If the operating diaphragm fails 6 1 the safety diaphragm 6 2 will take over the control function Simultaneously a red mark ing appears in the diaphragm rupture indi cator 12 response at approx 1 5 bar or medium will leak from the test connection of the actuator Replace the defective operating diaphragm 6 1 If the actuator stem leaks disassemble the actuator as described in section 4 2 Inspect the actuator stem for any grooves and re place the O rings 17 located in the actuator housing with new ones 4 1 Cleaning or replacing the plug Refer to Fig 1 on page 5 CAUTION The positioning springs are pre tensioned Take appropriate safety precautions If nec essary make an appropriate disassembly tool or use SAMSON disassembly tool order no 1280 3098 Remove the valve from the pipeline Un screw the control l
8. assembly Turning the set point adjuster 10 will change the spring force and the set point Type test The safety excess pressure valves SEV have been typetested by the German Technical In spectorate TUV Type test approval numbers are available on request Design and principle of operation CAL 1 1 3 2 P NA p P EA a a2 3 1 OI aK 33 P1 SN Lee p2 TUR 4 aM uy NL 7 3 Ng SM 3 4 FA TNA SY 5 2 7 D 15 DN 15 to 25 6 2 HAIE aT pm lug assembl 6 1 CS 0211 2 F 12 pug y Az P2222 7 A rese 1 1 Turned into plane of ST a projection z f Es 13 SH Gu i d Ees 8 oe 3 9 m a 10 le 2 Type 44 8 SEV DN 32 to 50 with threaded body 1 Valve body 1 1 Body stopper 2 Seat ring J Plug assembly 3 1 Valve plug 3 2 Plug nut 3 0 Plug stem 3 4 Plug spring 3 9 Plug stopper 10 3 6 Guide nipple 11 6 Actuator housing 12 6 1 Operating diaphragm 13 6 2 Safety diaphragm 14 7 Actuator stem 15 8 Spring assembly 16 9 Spring plate 17 Fig 2 Sectional drawings of Type 44 8 and Type 44 7 E Cr SIE SIR gen BE NAY DD He x QS Yee zzz N REESE SST y m a zum 6 NIT BZ SEF oS SN NS Z ASSET ER c N Turned into 17 plane of projection Type 44 7 DN 32 to 50 with flanged body Set point adjuster Control line Diaphragm rupture indicator Type 44 8 only Body screws Intermediate ring Diaphragm plate nut
9. ine 11 Disassemble the spring assembly 8 using a suitable tool e g SAMSON disassembly tool 1280 3098 EB2723EN 7 Maintenance Ma Unscrew the body stopper 1 1 3 Unfasten the body screws 13 6 8 Remove the actuator housing 6 with in termediate ring 14 Unscrew the plug nut 3 2 Remove the valve plug 3 1 from the plug stem For DN 15 to 25 Unscrew the guide nipple 3 6 of the plug assembly 3 using the socket wrench order no 1280 3001 and pull it out You can make this wrench from a GEDORE screwdriver bit IN 19 19 for example by drilling a 17 mm hole 17 into the 19 mm hexagon bit For DN 32 to 50 First unscrew the plug stopper 3 5 then pull out the plug assembly 3 Thoroughly clean the seat and plug as sembly 3 and replace parts if dam aged Check the control line 11 for any blockages If the seat ring 2 is damaged unscrew it and replace it with a new one Reassemble the valve in reverse order of the steps above observing the tightening torques specified in Table 1 on page 4 EB 2723 EN 4 2 Replacing the diaphragm Refer to Fig 1 on page 5 CAUTION N The positioning springs are pre tensioned Take appropriate safety precautions If necessary make an appropriate disassembly tool or use the SAMSON disassembly tool order no 1280 3098 1 Remove the valve from the pipeline 2 Unscrew the control line 11 Disassemble the sp
10. ring assembly 8 us ing an appropriate tool e g SAMSON disassembly tool 1280 3098 3 Unfasten the body screws 13 Remove the actuator housing 6 with in termediate ring 14 4 Unscrew the diaphragm plate nut 15 and remove it from the actuator stem 7 Then lift off the diaphragm plate 16 5 Replace the diaphragm s 6 For reassembly proceed in reverse or der observing the tightening torques as indicated in Table 1 on page 4 5 Nameplate 2 3 lt 6 10 7 8 2 Model number 2 Configuration ID 3 Date of manufacture A Type designation 5 Nominal pressure PN or ANSI Class 6 Kys or Cy coefficient Max perm temperature in C or F 8 Set point range in bar or psi 9 Max perm differential pressure Ap 10 Arrow indicating direction of flow Fig 4 Nameplate Nameplate 6 Customer inquiries If malfunctions or defects occur contact the SAMSON After sales Service for support The address of SAMSON AG its subsidiar ies representatives and service facilities worldwide can be found on the Internet at www samson de in a SAMSON product cat alog or on the back of these mounting and operating Instructions Should you have any inquiries please submit the following details Type nominal size of the valve and its set point range Order and model numbers see nameplate Upstream and downstream pressures Temperature and process medium Min and max flow rates
11. t is not operated for long periods of time Moreover a plant shutdown will relieve the operating diaphragms To monitor the pressures prevailing in the plant install pressure gauges both upstream and downstream of the valve 3 Operation 3 1 Start up Fill the plant very slowly on start up First open the shut off valve downstream of the excess pressure valve and then the shut off valve upstream of the excess pres sure valve When carrying out a pressure test on the sec tion of the pipeline equipped with the pres sure regulator make sure that the diaphragm actuator cannot be damaged by the test pressure To proceed remove the control line connected to the valve and seal the open port with a stopper accessories stopper 8323 0030 and seal 8412 0771 3 2 Set point adjustment Adjust the desired upstream excess pressure by means of the set point adjuster 10 of the spring plate 9 monitoring the upstream pressure indicated by the pressure gauge Turn the set point adjuster clockwise to in crease the set point pressure Turn the set point adjuster counterclock wise to decrease the set point pressure 3 3 Shut down First close the shut off valve upstream of the valve and then close the shut off valve down stream of the valve 4 Maintenance The valve is subject to natural wear Depending on the application conditions that prevail inspect the valve at appropriately scheduled intervals CAUTION
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