Samson 33-7 Page 1 Mounting And Operating Instructions Download

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Translation of original instructions

EB 2551-2 EN

Type 33-7 Safety Excess Pressure Valve (SEV)

Self-operated Regulators

Edition July 2020

Summary of Contents for 33-7

Page 1: ...Translation of original instructions EB 2551 2 EN Type 33 7 Safety Excess Pressure Valve SEV Self operated Regulators Edition July 2020 ...

Page 2: ... questions about these instructions contact SAMSON s After sales Service aftersalesservice samsongroup com 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 Definition of signal words Hazardous situations which if not avoided will result in...

Page 3: ...he 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 Installation 5 1 5 1 Installation conditions 5 1 5 2 Preparation for installation 5 3 5 3 Final installation 5 4 5 3 1 Installing the regulator 5 4 5 3 2 Cleaning the pipeline 5 4...

Page 4: ... 9 2 9 3 2 Replacing the seat and plug 9 4 9 3 3 Replacing the actuator s operating diaphragm 9 4 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 Certificates 14 1 15 Annex 15 1 15 1 Tightening torques 15 1 15 2 Lubricant 15 1 15 3...

Page 5: ...rces or any other external factors Î Refer to the technical data and nameplate for limits and fields of application as well as possible uses Reasonably foreseeable misuse The regulator is not suitable for the following applications Use outside the limits defined during sizing and by the technical data Use outside the limits defined by the additional fittings mounted on the regulator Furthermore th...

Page 6: ... 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 Furthermore 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 proces...

Page 7: ...pplies to the start up and shutdown procedures Start up and shutdown procedures fall within the scope of the operator s duties and as such 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 Refe...

Page 8: ... on the regulator depressurize all plant sections affected as well as the regulator Î Drain the process medium from all the plant sections affected as well as the regulator Î Wear personal protective equipment Referenced documentation The following documents apply in addition to these mounting and operating instructions Mounting and operating instructions for e g Type 2 N NI Strainer u EB 1015 Dat...

Page 9: ...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 Î Wear hearing protection when working near the valve 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 e...

Page 10: ...ivery note Î Information on safe use of the part affected u www samsongroup com en about samson material compliance reach regulation 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 Î If possible drain the process medium from all th...

Page 11: ...ble medium properties The regulator is designed for a process medium with defined properties Î Only use the process medium specified 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 Î Flush the pipelines before start up SAMSON s After sales Service can support you concerning lubric...

Page 12: ...1 8 EB 2551 2 EN ...

Page 13: ...1 or p2 10 Set point range 11 Order number 12 SAP number 13 QR code 14 Date of manufacture Fig 2 1 Regulator nameplate 2 2 Location of the nameplate Location of the nameplate Fig 2 2 Nameplate of Type 33 7 Regulator 2 3 Material numbers The material designation can be found on the nameplate 7 body material or you can contact us the configuration ID specification is needed to find out which materia...

Page 14: ...2 2 EB 2551 2 EN ...

Page 15: ...ssure pS It functions as an excess pressure valve and controls the main valve 1 The control pressure pS is transferred through the control line 12 and acts on the operat ing diaphragm 6 The control pressure pS drops when the upstream pressure p1 rises The force resulting from the control pressure pS acting on the operating diaphragm 6 and the forces created at the positioning springs 7 fall below ...

Page 16: ...g stem 5 Balancing bellows 6 Operating diaphragm 7 Positioning springs 8 Pilot valve 8 1 Filter 8 2 Set point springs 9 Set point adjuster 10 Control line for upstream pressure p1 10 1 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 of Type 33 7 ...

Page 17: ...he process medium may impair the proper functioning of the regulator We recommend installing a strainer e g SAMSON Type 2 NI upstream of the excess pressure valve u EB 1015 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 repai...

Page 18: ...age 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 excess pressure valve SEV by the German Technical Inspectorate TÜV according to the requirements stipulated in the AGFW Ger man District Heating Association document FW 504 see Table 3 1 The test mark is available on request Temperature range Depending on ...

Page 19: ...e on request It is not possible to type test valves in DN 200 and 250 since the test specification only applies to KVS 380 at the maximum However their design and function are identical to those of the typetest ed valve sizes Table 3 2 KVS coefficients and xFZ values Terms for noise level calculation according to VDMA 24422 edition 1 89 Valve size DN 65 80 100 125 150 200 250 KVS coefficient 50 80...

Page 20: ... 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 fittings 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 60...

Page 21: ...EB 2551 2 EN 3 7 Design and principle of operation Dimensional drawings L H ØD H2 Fig 3 3 Dimensions ...

Page 22: ...3 8 EB 2551 2 EN ...

Page 23: ...dimensions of the units to be lifted and transported in order to select the appropriate lifting equipment and lifting accessories Refer to the transport documents and the De sign and principle of operation section 4 2 Removing the packaging from the regulator The tested regulator is delivered as an as sembled unit Proceed as follows to lift and install the regu lator Î Do not open or remove the pa...

Page 24: ...andling 15 to max 55 kg taking into account age gender and physical fitness Î Observe the occupational health and safety regulations valid in the country of use DANGER WARNING WARNING Risk of personal injury due to the regulator tipping Î Observe the regulator s center of gravity Î Secure the regulator against tipping over or turning Our after sales service can provide more de tailed transport and...

Page 25: ...errupting work for longer periods of time Î Make sure that the axis of the pipeline is always horizontal during lifting and the axis of the plug stem is always vertical Lifting 1 Attach one sling to the flange of the body and to the rigging equipment e g hook of the crane or forklift see Fig 4 1 2 Carefully lift the regulator Check wheth er the lifting equipment and accessories can bear the weight...

Page 26: ... fluences e g impact Î Secure the regulator in the stored posi tion against slipping or tipping over Î Do not damage the corrosion protection paint surface coatings Repair any damage immediately Î Protect the regulator against moisture and dirt Store it at a relative humidity of less than 75 In damp spaces prevent condensation If necessary use a drying agent or heating Î Make sure that the ambient...

Page 27: ...SON if the reg ulator conditions or state of the medium process deviate Î Install the regulator free of stress and with the least amount of vibrations as possible Read information under Mounting position and Support or suspension in this section Î Install the regulator allowing sufficient space to remove the actuator and valve or to perform service work on them Mounting position To ensure that the...

Page 28: ... or suspension of the installed regula tor and the pipeline Depending on the regulator version and mounting position the valve actuator and pipeline must be supported or suspended Do not attach supports directly to the regula tor Note NOTICE Standard mounting position suspended All versions Not permissible Not permissible Fig 5 1 Mounting position ...

Page 29: ... or required additional fit tings have been installed or prepared as necessary before installing the valve see the Design and principle of operation section Proceed as follows Î Lay out the necessary material and tools to have them ready during installation work Î Flush the pipeline before installing the regulator The plant operator is responsible for cleaning the pipelines in the plant Î Check an...

Page 30: ...serve the flow direction through the valve The arrow on the valve indicates the direction of flow 4 Make sure that the correct flange gaskets are used 5 Bolt the pipe to the valve free of stress 6 Slowly open the shut off valves in the pipeline after the valve has been in stalled 5 3 2 Cleaning the pipeline We recommend additionally flushing the pipeline without the installed regulator be fore sta...

Page 31: ...to process medium escaping Î Do not start up the regulator until all parts have been mounted Risk of hearing loss or deafness due to loud noise Noise emission e g cavitation or flashing may occur during operation caused by the process medium and the operating condi tions Î Wear hearing protection when working near the regulator DANGER DANGER WARNING Risk of burn injuries due to hot or very cold co...

Page 32: ...e 5 Rework any parts that leak and repeat the leak test Tip 5 4 2 Pressure test The plant operator is responsible for performing the pressure test SAMSON s After sales Service can support you to plan and perform a pressure test for your plant Risk of valve damage due to a sudden pres sure increase and resulting high flow veloci ties Slowly open the shut off valves During the pressure test make sur...

Page 33: ...on water has dried off 3 Insulate the regulator and pipes convey ing the process medium using insulation material with a water vapor barrier If a control line is to be routed through the insulation special care must be taken with the sealing since slight changes in shape may occur The insulation thick ness depends on the medium tempera ture and the ambient conditions 50 mm is a typical thickness R...

Page 34: ...5 8 EB 2551 2 EN ...

Page 35: ...eafness due to loud noise Noise emission e g cavitation or flashing may occur during operation caused by the process medium and the operating condi tions Î Wear hearing protection when working near the valve WARNING WARNING WARNING Re Risk of personal injury due to process medium escaping Î Do not start up the regulator until all parts have been mounted Before start up or putting the valve back in...

Page 36: ...in pressure and high flow velocities which can damage the valve 3 Check the regulator to ensure it functions properly 6 2 Starting up the plant 1 Open the shut off valves slowly prefera bly starting from the upstream pressure side Afterwards open all the valves on the consumer side downstream of the regulator 2 Fill the plant slowly with the process me dium Avoid pressure surges 3 Make sure that t...

Page 37: ... Do not unscrew the control line while the valve is pressurized Risk of hearing loss or deafness due to loud noise Noise emission e g cavitation or flashing may occur during operation caused by the process medium and the operating condi tions Î Wear hearing protection when working near the valve WARNING WARNING WARNING 7 1 Adjusting the set point Î The required upstream pressure is set by turning ...

Page 38: ...7 2 EB 2551 2 EN ...

Page 39: ...nd plug in the main valve or pilot valve are worn or leak ÎContact SAMSON s After sales Service Insufficient pressure pulses on the operat ing diaphragm ÎClean the control line and screw fittings Foreign particles blocking the plug in the main valve or pilot valve ÎContact SAMSON s After sales Service Control line blocked ÎClean the control line and screw fittings Strainer blocked ÎClean the strai...

Page 40: ...er cases Putting the regulator back into operation after a malfunction See the Start up section Contact SAMSON s After sales Service for malfunctions not listed in the table The malfunctions listed in section 8 1 are caused by mechanical faults and incorrect regulator sizing In the simplest case the functioning can be restored following the recommended action Exceptional operating and installation...

Page 41: ... may become very hot or cold Risk of burn inju ries Î Allow components and pipelines to cool down or warm up to the ambient tem perature Î Wear protective clothing and safety gloves Risk of personal injury due to residual process medium in the regulator While working on the regulator residual WARNING WARNING WARNING process medium can escape and depending on its properties may lead to personal in ...

Page 42: ...ay out the necessary material and tools to have them ready for the service work 2 Put the regulator out of operation see the Decommissioning section Note Tip We recommend removing the regulator from the pipeline before performing any service work see the Removing the regulator from the pipeline section The following service work can be per formed after preparation is completed Clean or replace the...

Page 43: ... it if nec essary Installing the filter 1 Insert new or cleaned filter 42 2 Place a new seal 50 on the strainer stopper 13 3 Screw the strainer stopper 13 into the body of the pilot valve Observe the specified tightening torques see Tighten ing torques in the Annex 50 13 42 13 Strainer stopper 42 Filter 50 Seal Fig 9 1 Pilot valve The order numbers of the seal and the filter are listed under Acces...

Page 44: ...ee Annex for details on accessories 9 3 2 Replacing the seat and plug Risk of TÜV approval based on AGFW worksheet FW 504 becoming void Î Consult SAMSON s After sales Service before you change parts or perform service or repair work on TÜV tested Type 33 7 Regulators Further information is available in Annex After sales service 9 3 3 Replacing the actuator s operating diaphragm Risk of TÜV approva...

Page 45: ...hot or cold Risk of burn inju ries Î Allow components and pipelines to cool down or warm up to the ambient tem perature Î Wear protective clothing and safety gloves Risk of personal injury due to pressurized DANGER WARNING WARNING components and process medium being discharged Î Do not loosen the control line while the valve is pressurized Risk of hearing loss or deafness due to loud noise Noise e...

Page 46: ...tream side of the regulator 2 Close the shut off valve 6 on the down stream side of the regulator 3 Depressurize the plant 4 Completely drain the pipelines and valve 5 If necessary allow the pipeline and reg ulator components to cool down or warm up to the ambient temperature ...

Page 47: ...rocess medium in the regulator While working on the regulator residual process medium can escape and depending on its properties may lead to personal in jury e g chemical burns Î Wear protective clothing safety gloves and eye protection Before removing the valve make sure the following conditions are met The regulator is put out of operation see the Decommissioning section WARNING WARNING WARNING ...

Page 48: ...11 2 EB 2551 2 EN ...

Page 49: ...After sales Service NOTICE NOTICE 2 Send an e mail u retouren samsongroup com to register the return shipment including the following information Type Material number Item numbers of accessories Original order Completed Declaration on Contamination which can be downloaded from our website at u www samsongroup com Service Support After sales Service After checking your registration we will send you...

Page 50: ...12 2 EB 2551 2 EN ...

Page 51: ...B 2551 2 EN 13 1 Disposal 13 Disposal Î Observe local national and internation al refuse regulations Î Do not dispose of components lubricants and hazardous substances together with your household waste ...

Page 52: ...13 2 EB 2551 2 EN ...

Page 53: ...551 2 EN 14 1 Certificates 14 Certificates The EU declaration of conformity is provided on the next page EU declaration of conformity in compli ance with Pressure Equipment Directive 2014 68 EU on page 14 2 ...

Page 54: ...xamination Certificate Modul B Module B Zertifikat Nr Certificate no 01 202 931 B 13 0025 Angewandtes Konformitätsbewertungsverfahren Conformity assessment procedure applied Modul D Module D Zertifikat Nr Certificate no CE 0062 PED D SAM 001 16 DEU rev A Dem Entwurf zu Grunde gelegt sind Verfahren aus The design is based on the procedures specified in the following standards DIN EN 12516 2 DIN EN ...

Page 55: ...er 13 SW 19 22 Control line connection 10 11 12 22 15 2 Lubricant SAMSON s After sales Service can support you concerning lubricants and sealants approved by SAMSON 15 3 Tools SAMSON s After sales Service can support you concerning tools approved by SAMSON 15 4 Accessories Table 15 2 Accessories with item num ber For pilot valve 8 Item number Filter 42 0550 0751 Seal 50 8413 1569 ...

Page 56: ...The addresses of SAMSON its subsidiaries representatives and service facilities worldwide can be found on our website u www samsongroup com or in all SAMSON product catalogs Required specifications Please submit the following details Device type and nominal size Valve balanced by a bellows or diaphragm Model number or material number Upstream and downstream pressure Temperature and process medium ...

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Page 58: ...2020 08 14 English SAMSON AKTIENGESELLSCHAFT Weismüllerstraße 3 60314 Frankfurt am Main Germany Phone 49 69 4009 0 Fax 49 69 4009 1507 samson samson de www samson de EB 2551 2 EN ...

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