in Control Valve Engineering

GLOBAL PRESENCE

AIR TORQUE · CERA SYSTEM · KT-ELEKTRONIK · LEUSCH · PFEIFFER
PRECOGNIZE · RINGO · SED · STARLINE · UBIX · VDH PRODUCTS · VETEC

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Global presence with a local touch – SAMSON has e­ njoyeda history of growth for over a century. Shortly after the­company was founded in 1907, SAMSON established partnerships with renowned trading houses in several ­European
countries to efficiently market our products abroad.
The f­ormation of the Technical Sales Department in 1949
laid the foundations for the expansion of SAMSON‘s­international sales and service network recognized for its
expertise and efficiency.

A strong partner – Today, SAMSON is a worldwide
leader in the manufacture of expertly engineered control
valves and accessories for all industrial processes. Noted
manufacturers of special valves, such as AIR TORQUE,­CERA SYSTEM, ­LEUSCH, PFEIFFER, RINGO VÁLVULAS,STARLINE and VETEC, belong to SAMSON.
Local customer support – With over 50 largely ­independent
subsidiaries and more than 220 representatives or­engineering and sales offices, SAMSON is on hand toprovide local customer service all over the world. Each­
year, new offices are established to further strengthen our
local presence. Quick service for our SAMSON products­anywhere in the world is a matter of course.

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CONTROL VALVES IN MODULAR DESIGNIn any case
Efficient solutions – SAMSON‘s expertise in control ­valve
engineering covers all processes in industrial plants.
Our ­extensive experience gained over the years fromthe design, development and manufacture of optimally­engineered solutions serves as the basis for mastering new­challenges. The wide range of products proven in practice
can be ­customized in close cooperation with our customers
to p­ rovide a commercially acceptable solution that meetsthe requirements of even the most complex applications.

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Modular design – With their flexible, modular design, our
SAMSON control valves can be tailored to the ­specific­control task, which allows them to meet even the mostchallenging requirements under severe operating condi­
tions.
SAMSON can supply modular control valves with globe,
angle and three-way bodies in all common pressure ratingsand materials at short notice. The valves are designed in­accordance with the ANSI, DIN or JIS standards and available with different flange types and welding ends.

The right actuator – Pneumatic actuators with a rolling­diaphragm and springs evenly arranged in the actuatorcase are made to precisely fit on valves over robust yokes,
completing the compact design of our SAMSON control
valves.
The fail-safe action of SAMSON actuators can be reversedin the field, requiring no additional parts. The connector
mechanism that fastens the actuator to the valve stem allows
the travel and thrusts to be varied.
Actuators with manual overrides ensure that the process cankeep running in emergency mode, even in the event of acontrol signal or power supply failure.

Innovative valve accessories – Positioners and limit switches by SAMSON ensure the safe operation of our customers‘
plants.
Small to medium-sized actuators mounted on globe valves
are designed for integral positioner attachment, eliminating
the need for external piping. In all other cases, the NAMUR
rib at the actuator yoke ensures that the valve accessories
are mounted safely.
Attachment of our positioners to rotary actuators complies
with VDI/VDE 3845 requirements.

5Efficient solutions
Optimized to the max –Thanks to the modular design of our SAMSON control
valves, their purchase price aswell as the costs for energy, maintenance and repair incurred during the valve‘s entire service life
are comparatively low. ­Especially when it comesto valves designed for critical media that consume
a lot of energy, the purchase price accounts for only
a fraction of the total cost of ownership.
The modular valve design allows us to provide a large­number of valve versions configured from a small number ofcomponents. The plugs designed for the smaller valve sizesof our Type 3241 for example, can be used for reduced KVS
coefficients up to DN 50 or NPS 2.
In addition, the seat design allows the valve trims to beadapted easily to changed process data.

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The dimensions of the bellows and packings are identical up
to DN 80. As a result, fewer spare parts have to be kept instock despite the wide variety of KVS coefficients.
True, a metal bellows costs more than a packing. But when
the packing needs to be replaced for the first time, these
extra costs will soon be forgotten in view of the considerable
plant downtime caused.

Often, an actuator with a greater actuating force is more
expensive than a pressure-balanced solution. However, themore powerful actuator provides a lower hysteresis and­leakage rate, and it may not be necessary to repeatedly
replace worn-out gaskets.
The reliable and economically viable solutions by SAMSON
ensure the competitiveness of our customers in the­international market.

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PRESSURE LETDOWN IN GASES

Low-noise operation
Theoretical insights – When reducing the pressure in gases and vapors, the medium expands as it passes throughthe valve and reaches high flow velocities even at small­pressure drops. As a result, a turbulent mixing zone is created downstream of the vena contracta where the pressureand density fluctuate considerably. As the differential pressure ­increases, the flow velocity may exceed the speed ofsound at ­certain locations. This causes the turbulent mixing
zone to be overlapped by shocks. This phenomenon exposes the valve ­components to extreme mechanical stress andleads to noise emissions exceeding 100 dB(A).
Empirical data applied – SAMSON has carried out­extensive tests on in-house test benches operated by steam,water and air to investigate how and why noise develops incontrol valves as well as to find ways of optimizing the noise­behavior patterns. To achieve a low-noise pressure letdown,
the outlet velocity must be restricted to Mach 0.3. This helps
avoid secondary sources of noise and allows our SAMSON
flow dividers to perform to their full potential: they keep the
turbulent zone directly downstream of the vena contracta incontrol and reduce the sound level by as much as 30 dB(A).

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Accurate noise calculations – SAMSON bases noise emission calculations on the internal sound power, which can becalculated using a theoretical formula and acoustical efficiency factors determined empirically. This method is used
to precisely calculate noise transmission loss, the effect of
insulation, noise emission at a remote location or when venting to the atmosphere.
With the objective of improving existing standards andmeeting customer requirements, we at SAMSON are constantly investing in our high-performance test rigs.
Effective solutions – A control valve can be adapted to an
existing pipeline by installing a silencer downstream of thevalve. This silencer restricts the pressure drop across thevalve at full load and expands the valve outlet to achieve an
outlet velocity that does not exceed Mach 0.3. A low-noise
momentum exchange with the surrounding medium is madepossible by using a perforated plug. A considerable noise
reduction is achieved by the design consisting of a silencer,
perforated plug and flow divider.

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THROTTLING SERVICE WITH LIQUIDS

15
13.5

Input pressure

12
10.5

PressureMulti-stage pressure letdown

97.5

Output pressure
Vapor pressure

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4.5
3
1.5

Flow pathPressure graph:With AC-trim

0

Without AC-trim

Mastering cavitation
When bubbles implode – Handling liquids at moderate­pressure drops does not pose any difficulties for control
valves made of suitable anti-corrosive materials. However,
severe problems emerge when cavitation occurs, accompanied by its numerous damaging side effects, such as surface
erosion, unacceptably high noise emissions and unsteadyflows. Almost always, cavitation results in critical interruptions of plant operation, costly repairs or even requires
control valves to be replaced and the pipeline layout to bechanged.
Perfect solution – The cavitation factor xFz introduced by SAMSON in 1973 is the basis forinternational noise p­ rediction standards andspecifies at which pressure ratio cavitation
starts. As a result of elaborate tests and calculations performed at SAMSON, the standard
valves have been optimized to prevent cavitation by developing special plug designs and anti-cavitation trims with high xFz coefficients to keep
the valves free of vibration and cavitation over theentire load range.

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Flow velocity

For example, a seat-guided and shape-optimized parabolic
plug with special flow contours and a raised seat yields thelowest possible pressure recovery. At high valve loads, thexFz coefficient can be further increased by using upstream
attenuation plates to prevent cavitation.
Multi-stage plugs with double guiding sized to achieve thesame differential pressure ratio at every stage across theentire load range are particularly suitable for applications
involving high pressure drops.
Cavitation under control – In cases where cavitation cannot
be prevented using the primary measures at hand, the­control valve needs to be sized to withstand the adverse
effects of cavitation. SAMSON can provide the perfect solution in any case, thanks to our modular valve design withflow coefficients determined over the entire travel range on
in-house test benches as well as a valve sizing software thattakes into account the control loop behavior under all operating conditions.

11MULTI-PHASE FLOWS

Rugged and reliable
Flow know-how – As there is no binding calculation­standard, a high level of expertise is required when sizing
valves intended to control multi-phase flows, e.g. a gas-liquid­mixture. Special consideration must be given to the increasein volume and velocity that occurs during the expansion of
the mixture as well as to the fact that the mixture has a lower
sound velocity than its individual components. Thanks to ourexpertise, our SAMSON valves are ideally sized and produce non-choked flows, which prevent excessive mechanicalstress on the valves.
Eliminating the effects of erosion – Multi-phase flows
containing a large amount of gas and solid particles,­
such as carbon or minerals, have a severely erosive effecteven at low flow velocities. The damage becomes visible
as d­ estroyed material surfaces on the seat, plug, plug stem
and body. Angle valves with flow-to-close design, ceramicor ­carbide trims and downstream anti-wear sleeves have
proven ideal for controlling such flows.

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The flashing phenomenon – SAMSON set up a test rig
to study flashing and valves under operating conditions.
In cooperation with Hamburg University of Technology,
SAMSON successfully developed solutions for proper sizing. The optimal valve design – both for two-phase flow
and flashing service – proved to be a one-stage valve
with a considerably reduced seat bore and a seat-guided plug, which provides sufficient space for the ­expansionof the gas or vapor and ensures continuous, nonerosive downstream flow. Such valves can easily be configured from SAMSON‘s modular valve components.
One of the most essential components is the V-port plug.
Thanks to its rugged seat guiding and asymmetrical
ports, the plug reliably prevents mechanical vibration and­resonance oscillations. It ensures safe operation, especially
under c­ ritical operating conditions such as flashing.

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VALVES FOR HIGH FLOW RATES

Sizing matters
Well sized – A decisive factor for the efficient operation ofindustrial plants involves handling high flow rates at smallpressure drops while consuming little energy. In addition to
globe valves in large sizes, valves with a high flow capacity
and low friction coefficient are best suited for such tasks,
e.g. rotary plug valves, butterfly valves or ball valves withpowerful, low-friction rotary actuators.
Tight shut-off – Depending on the task at hand, the valves
are expected to provide a high flow capacity as well as
ensure tight shut-off and low fugitive emissions, show an­excellent control quality or perform reliably in case of fire.
Rotary valves meet tight shut-off requirements by using a14

multi-eccentric closure member or a floating, flexible orlive-loaded seat – or by combining both designs.
For the actuator to be sized effectively, certain factors need
to be known, such as the friction, closing and breakaway
torques depending on the pressure drop across the valve
as well as the dynamic torques that additionally dependon the valve position, process medium and pressure ratio.
SAMSON operates high-performance test benches to determine and optimize the valve-specific coefficients. Apartfrom cost-effective piston actuators, our product line also includes low-friction rotary actuators with rolling diaphragms
for an excellent control performance.

Heavy-duty valve series – Our heavy-duty valve series,
e.g. SAMSON Series 590, available in sizes up to DN 700
or NPS 20 keeps high flow rates safely under control, evenat high pressures and temperatures.
Butterfly valves – In our butterfly valves, the multi-offset disk
design guarantees a low initial breakaway torque and accurate control, even at very small opening angles.
Segmented ball valves – An excellent rangeability and finecontrol characteristic are the main features of our segmented ball valves, which have a V-shaped port incorporated
into the ball.

MAXIFLUSS rotary plug valves – The MAXIFLUSS rotaryplug valves are ideal for controlling high flow rates. The
cross-sectional area between the seat and plug is fully released, leaving the flow path unrestricted. At the same time,
controllability remains accurate even at small flow rates.
The double-eccentric seat-plug geometry allows the valve toopen without initial breakaway torque so that is can be operated up to a rangeability of 200:1. Sophisticated details,
such as the rugged splined connection between plug andshaft, guarantee safe operation of the valves.

Ball valves – The ball valves feature a floating ball that
ensures tightest shut-off while a trunnion-mounted bearing
helps achieve better control properties.

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PRODUCTS FOR VALVE COMMUNICATION

Smart data
Stay well informed – Integrating control valves into the­process control system has a significant positive effect oncontrol accuracy, product quality and plant efficiency.
With the help of smart valve communication, predictive
maintenance becomes possible and plant availability is­increased. ­SAMSON‘s smart valve positioners are the modules used to integrate the field units into the control system.
They g­ uarantee a reliable data exchange in the process andquickly detect faults and malfunctions.
Positioner integration – SAMSON offers innovative, selfcalibrating positioners with integrated EXPERTplus valve­diagnostics for all common communication protocols.
The positioners with HART® communication combine theproven mA technology with digital communication.

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The major benefit of PROFIBUS® positioners is their costeffective wiring: only a single cable is needed for data
­transmission and the power supply.
FOUNDATION™ fieldbus positioners set the trend towards
more distributed networks. They contain function blocks thatenable them to act as fully fledged process controllers.
With PROFINET over Ethernet-APL we support
the latest communication
technology for the process industry. This newtechnology achieves
fast data transmission rates even inhazardous
areas(intrinsic safety).

Intuitive operation – Automatic start-up and a proven­operating structure in all our digital positioners as well as­numerous details, such as initialization at the push of a­button, convenient operation using one rotary pushbutton,
a display that is easy to read and whose reading direction
can be turned by 180°, contribute to making start-up andoperation easier for the user.
Our positioners are easily adapted to the control task at
hand – either on site or, in Series 3730, 3731, 3793 and3797 Positioners with diagnostics, on a computer using our­TROVIS-VIEW software.
The new positioner generation TROVIS 3793 and TROVIS
3797 leaves nothing to be desired. These positioners have amodular design and generate a high air capacity. Variable
outputs, e.g. double-acting control, can be achieved by using
exchangeable pneumatic modules that can be retrofitted.

Optional additional functions, such as limit switches, position feedback orbinary inputs and outputs,
can be added to the positioner onsite as option modules. Pressure
sensors and the integrated
EXPERTplus valve diagnostics provide extensive high-performance­diagnostic functions.
We have added the new
TROVIS SAFE series to ourrange of positioners specially for use in safety-instrumented systems. The positioners include partial stroke
testing and ready configured for the use on on/off valves.

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FOR THE GOOD OF THE ENVIRONMENT

Proven to be reliable
Keeping the air clean – Environmental protection and thesustainable use of natural resources have become key issues in modern society. Laws and regulations, such as the
Clean Air Act in the United States or TA Luft in Germany, lay
down limits for emissions produced by industrial plants. The
comparable evaluation of limits is defined in international
standards, such as FCI 91-1 or ISO 15848.
SAMSON valves assist our customers in observing theselimits. Depending on the requirements, the plug stem issealed by a self-adjusting V-ring packing or an adjustablepacking. In addition, a bellows seal can be used to prevent
leakage at the plug stem.

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A matter of packing – We have developed packings for our
SAMSON valve series that meet the highest requirements.
Temperatures ranging from –50 to +400 °C or even temperature ranges between –200 and +550 °C, depending on
the application, are possible.
For any application – The maintenance-free, spring-loaded V-ring packing made of a PTFE-carbon compound with
its special long-life lubricant can be used for most process
media. A number of special packings is available for severe-service applications, e.g. involving urea or water that
contains calcium carbonate, process media that crystallize
out or polymerize, or for molten salt.

A groundbreaking invention – The most effective sealing
solution is the metal bellows, one of the groundbreaking
inventions of SAMSON. We still manufacture multi-layer
bellows made of stainless steel for toxic or cryogenic media.
Absolutely leak-tight – SAMSON‘s metal bellows guaranteethat valves meet stringent fugitive emissions requirements. If
the bellows is heated or flushed to prevent crystallizing media or deposits from clogging it up, the bellows can guarantee zero emissions throughout the valve‘s entire service
life without creating friction or requiring maintenance. This
ensures the safety and environmental compatibility of ourcustomers‘ plants, even in critical applications.

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SMART VALVE TECHNOLOGY

Fully flexible
Meeting the challenge – With sophisticated control valves,
SAMSON provides the perfect answer to demanding
process requirements that cannot be met by standard valve
versions.
SAMSON has equipped the control valves with special
components and accessories to satisfy even the most­demanding requirements. In addition, we have designed
highly specialized valve series for high-performance­applications.
On top of that, SAMSON develops and manufactures
valves made of materials that are difficult to machine, suchas d
­ uplex or high-alloy steels.
The subsidiaries of SAMSON, such as AIR TORQUE, CERASYSTEM, LEUSCH, PFEIFFER, RINGO VÁLVULAS, STARLINE
and VETEC round off the product line and offer special solutions.

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VETEC for example, has specifically developed the VNG
valve to let down the pressure in natural gases that have only
been purified preliminarily and still contain dirt ­particles.
The valve‘s throttling system features a patented jet nozzle
and can handle abrasive liquids and solid particles, even at
differential pressures of more than 400 bar. In addition, it
complies with the strict noise emission regulations, leaving
nothing to be desired.

Heating jackets – Heating jackets ensure optimal condensate drainage and allow the control valves to be used evenfor media with a tendency to crystallize or congeal.
Tandem actuators – SAMSON‘s tandem actuators ensure
tight shut-off even at high differential pressures or low supply air pressures.
Valve accessories – Intricately hooked-up accessories, suchas supply air reducing stations, boosters, lock-up valves, solenoid valves and limit switches, enhance the positioners’
functions, allow for fast response times and make the control
valves fit for all desired fail-safe actions.

Modular micro-flow valves – Our micro-flow valves havebeen specifically developed to control the lowest flow rates
in pilot plants or technical research facilities. They are­available in sizes up to DN 25 or NPS 1.
Hygienic and aseptic valves – Our valves for hygienic
and aseptic applications are made of stainless steel. Their­bodies are suitable for CIP (cleaning-in-place) or SIP (sterilization-in-place). The suitability of materials and designs
used is certified by, for example FDA, EHEDG and 3A.

Self-operated regulators – Self-operated regulators offer asimple solution for all applications in which the controlled
variable is to be maintained at a constant value. If sizedproperly, they work with low noise emissions and provide
stable control even at smallest loads.

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GLOBAL AFTER-SALES SERVICE

D & FI E L DSEYI C E AC A D E M

Customer proximity
SAMSON has a global service network in over 50 countries
for fast support at the customer‘s, keeping plant downtime
to a minimum.
Our experienced SAMSON staff supports customers during
plant start-up, maintenance and repair.
All SAMSON sites have their own workshop and storage facilities, which allows us to provide spare parts at short notice.

To make the expertise available where it is needed,­SAMSON offers comprehensive service training either at
specialized workshops or on the job, including training
schemes tailored to our customers’ needs.
SAM VALVE MANAGEMENT, a web-based diagnostic toolby ­SAMSON, can be used for remote monitoring aroundthe clock from anywhere in the world.
Configuration and operation of our controllers andvalve ­
accessories is made easy and cost-effective by­TROVIS-VIEW, a software solution developed by SAMSON.
EXPERTplus, the SAMSON valve diagnostics integrated into
the positioner, allows for predictive maintenance while
the process is running. The positioner indicatesthe maintenance state of the control valve it ismounted on in compliance with NAMUR recommendation NE 107.

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Concepts for the future – Due to our long corporate­tradition and constant growth, logistics have always beenan ­important issue at SAMSON. Nevertheless, requirements have increased over the past years. Technology is­advancing at an increasingly faster pace. Short innovation
cycles ­demand short-term investment. To remain a proficient­partner even under these changing conditions, SAMSON
continues to invest in its logistics facilities to ensure that weare able to respond quickly, flexibly and in line with demand.

The last stage that the control valves pass on their way
through the logistics center is the sunlit final assembly hall.
At modern workplaces, the painted components are­assembled, adjusted and checked to make sure the final
products comply with customer specifications. State-of-theart test equipment, sufficient work space, efficient conveying
and stacking systems as well as pleasant offices create arelaxed and friendly environment for the final acceptancetest of SAMSON‘s high-quality control valves performed by
the customer.

Everything under one roof – The logistics center is theheart of a logistics system that ensures the availability of
our SAMSON products. We are able to manufacture 5,000
high-quality control valves at the Frankfurt headquarters
each month as semi-finished products and castings are
kept in stock to meet unscheduled demands. In addition,­
foresighted production of components and ­peripheral­devices as well as the quick final assembly according tocustomer ­specifications take place on short routes under
the watchful eye of an ISO 9001 certified quality assurance­system.

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SAMSON AT A GLANCE

STAFF

PRODUCTION SITES– Worldwide 4,500– Europe 3,600– Asia 600– Americas 200– Frankfurt am Main, Germany 1,900– SAMSON Germany, Frankfurt, established in 1916
Total plot and production area: 150,000 m²– Chemicals and petrochemicals– Food and beverages– Pharmaceuticals and biotechnology– Oil and gas– Liquefied Natural Gas (LNG)– Marine equipment– Power and energy– Industrial gases– Cryogenic applications– District energy and building automation– Metallurgy and mining– Pulp and paper– Water technology– Other industries

PRODUCTS– Valves– Self-operated regulators– Actuators– Positioners and valve accessories– Signal converters– Controllers and automation systems– Sensors and thermostats– Digital solutions

SALES SITES– More than 50 subsidiaries
in over 40 countries– More than 200 representatives– SAMSON Turkey, Istanbul established in 1984
Total plot and production area: 11,100 m²– SAMSON USA, Baytown, TX, established in 1992
Total plot and production area: 20,000 m²– SAMSON China, Beijing, established in 1998
Total plot and production area: 47,000 m²– SAMSON India, Pune district, established in 1999
Total plot and production area: 28,000 m²– SAMSON Russia, Rostov-on-Don, established in 2015
Total plot and production area: 24,000 m²– SAMSON AIR TORQUE, Bergamo, Italy
Total plot and production area: 27,000 m²– SAMSON CERA SYSTEM, Hermsdorf, Germany
Total plot and production area: 14,700 m²– SAMSON KT-ELEKTRONIK, Berlin, Germany
Total plot and production area: 1,100 m²– SAMSON LEUSCH, Neuss, Germany
Total plot and production area: 18,400 m²– SAMSON PFEIFFER, Kempen, Germany
Total plot and production area: 20,300 m²– SAMSON RINGO, Zaragoza, Spain
Total plot and production area: 19,000 m²– SAMSON SED, Bad Rappenau, Germany
Total plot and production area: 10,400 m²– SAMSON STARLINE, Bergamo, Italy
Total plot and production area: 27,000 m²– SAMSON VDH PRODUCTS, the Netherlands
Total plot and production area: 12,000 m²– SAMSON VETEC, Speyer, Germany
Total plot and production area: 27,100 m²

SAMSON AKTIENGESELLSCHAFT
Weismuellerstrasse 3 · 60314 Frankfurt am Main, Germany
Phone: +49 69 4009-0 · Fax: +49 69 4009-1507
E-mail: samson@samsongroup.com
Internet: www.samsongroup.com

2022-11 · WA165 EN

INDUSTRIES AND APPLICATIONS– SAMSON France, Lyon, established in 1962
Total plot and production area: 23,400 m²