Chapter 1 Introduction

Table of contents
1. Introduction
1.1 Book introduction ��001
1.1.2. Scope of topics ��002
1.1.3. How to use this book? ��003
1.1.4. Structure and sequence ��003
1.2 SAMSON your Partner for Automation and Control ��004
1.2.1. An Innovative Leader in Global Markets ��005
1.2.2. Market segments ��006
1.3 Research and Development at SAMSON ��007
1.3.1. Optimized device integration �� 012
1.4 Production at SAMSON ��015
1.5 Quality assurance at SAMSON ��018
1.6 Logistic center and dispatch department ��020
1.7 SAMSON GROUP ��021
1.7.1. The associated companies �� 021
1.8 SAMSON’s Project execution ��030
1.9 Extract of reference installations ��031
1.10 Subsidiaries and Engineer and Sales Offices of SAMSON GROUP ��044
1.10.1. Extract of the subsidiaries ��045
SAMSON AG · MESS- UND REGELTECHNIK · Weismüllerstraße 3 · 60314 Frankfurt am Main · Germany

Phone: +49 69 4009-0 · Fax: +49 69 4009-1507 · E-mail: samson@samson.de · Internet: www.samson.de
Book introduction Page 001 of 052
1. Introduction
1.1 Book introduction
This book is intended primarily for those novice instrument engineers.
Control valves may be the most important, but sometimes the most neglected part of a
control loop. The reason is usually the instrument engineers unfamiliarity with the many
facets, terminologies, and areas of engineering disciplines such as fluid mechanics,
metallurgy, noise control, and piping and vessel design that can be involved depending
on the severity of service conditions.
Control valves are critical components of the most common control loops in industry.
Mass flow streams and heat capacities are controlled by means of final control elements,
process pressures are reduced in accordance with given requirements, and solutions
are provided with regard to safety regulations as, for example, in a refinery or nuclear
power plant. Unfortunately, the importance of control valves has been pushed into the
background in recent years, due to fascinating new technologies such as digital control
systems (DCS) or smart field instrumentation.
Figure 1.1.-1: Process monitoring system of brewery Beck´s

of Jungmann Systemtechnik GmbH & Co. KG1
1 http://www.jungmann.de

Page 002 of 052 Chapter 1. Introduction
Contractors and end users as well often fail to see, however, that product quality, plant
safety, and environmental pollution depend very much on the selection of a suitable
control valve.
The present situation is characterized by the fact that major investments of process
automation equipment are for the benefit of digital control systems, software, and smart field
instrumentation. On the other hand, industrial control valves have considerable apparently
fallen behind innovation arrears in spite of their importance with regard to product quality
and safety functions. The same situation applies for education and advanced training of
service technicians and engineers. A permanently increasing share of university education
and/or practical training is dedicated to electronics, whereas mechanics and related
disciplines, for example, materials technology, or fluid dynamics, play only a second rate
role.
The major intention of the authors is to highlight the importance of control valves again and
to familiarize students, service technicians and control engineers with valve technology
and valve applications in process industries. This book covers the basics of final control
elements and is divided into several „Learning Modules“. It is particularly suitable for
students and for self instruction. In order to allow a full understanding of accompanying
literature and other sources, important foundations, rules and basics are explained in
the initial chapters. The following parts concentrate on the application of control valves
including calculation, layout, and specification. The selection of a suitable control valve
has naturally a considerable influence on control accuracy, reliability, and service life. An
unsuitable body material, an undersized valve actuator, or poor range ability may have not
only a negative impact on product quality, but can even endanger major control functions
and plant safety. Although this book reflects the “state of art” and regards the latest
international standards, it does not presume special knowledge beyond basic algebra.
Therefore comprehensive derivations of mathematical equations are purposely omitted.
Limitations and uncertainties of calculations as well as common mistakes during valve
layout process are briefly mentioned.
1.1.2. Scope of topics

The term “Final Control Element” covers a wide range of various products. Even other
equipment such as speed controlled pumps or electrical final control products belong
by definition to this group, because they may ultimately effect a change of flow or static
pressure.
In order to limit the scope of this book, the meaning of final control elements shall apply
for control valves with pneumatic or electric actuators only. The increasing importance of
so-called “valve accessories” requires, of course, that these products are also covered.
Since control valves are usually part of a control loop, in order to control a given flow
rate or to regulate a certain pressure, the mathematical basics of control theory apply for
valves as well. Because of the very many books available dealing with control theories
and mathematical descriptions of transient responses, and to limit the size of this book,
mathematical equations and relationships are mentioned only as far as the understanding
of the reader requires.

Book introduction Page 003 of 052
1.1.3. How to use this book?

The information presented in this publication is for the general education of the reader.
This technical book is directed at all persons who work professionally with control valves
and, who have at least some basic knowledge. A structured representation of the various
topics was chosen because the substance is also intended for private studies. The
learning success depends essentially on three factors:
The previous experience of the reader.
The complex topic takes many areas of engineering sciences into account. Therefore
it will be easier for a technician or engineer, for example, to understand material
properties or the theory of the noise generation as a reader who has no previous
business experience in this specialized field.
The methods which make a solution of a problem possible.
A comprehensive and complicated calculation of the flow coefficient without a computer
would certainly frustrate the reader. The use of personal computers and specific
software make the calculation, however, a routine matter.
The motivation of the reader is an essential factor.
Therefore this book can neither replace a lack of motivation nor make up missing
prerequisites.
1.1.4. Structure and sequence

The main sections of this book can be read singly and even in an arbitrary order. Every
head section deals with a definite topic which is narrowly connected with the others as
well. Typical questions are listed as exercises. These make a self-control possible. The
following procedure has proved to be particularly efficient:
For the quick reader:
Read through the table of contents.
Study the head sections by “overflying”.
Select the desired chapter.
Read the interesting part carefully and perhaps make some notes.
For the reader who has to work on a special problem:

Read through the table of contents.
Study the head sections by “overflying”.
Select the desired chapter.
Identify the problem and process the information correspondingly.

1.2 SAMSON your Partner for Automation and Control

SAMSON - A name recognized worldwide as a synonym for high-quality work,
entrepreneurial spirit and innovative strength. The company is not only known for a
complete product line in instrumentation and controls, but also offers the most modern
integrated automation systems. The field of expertise extends from heating and air-
conditioning technology to applications in the largest chemical plants. SAMSON operates
wherever there is controlled flow of vapors, oil and gases, liquids, chemicals etc.
The history of SAMSON is filled with the spirit of invention. It started in 1907 when the
company was founded by Hermann Sandvoss. His first patent marked the beginning of
a development which still today represents one of the company’s main product lines:
self-operated regulators.
Since 1916, the manufacturing plant and head office have been located on the river Main
in Frankfurt, Germany. Here, the product development and manufacturing take place as
well as administration and warehousing.
Figure 1.2.-1: SAMSON AG in Frankfurt is the heart of the worldwide-operating SAMSON GROUP.
The progressive, yet traditional management team is committed to the name SAMSON
and the quality in technical competence and partnership it stands for.

SAMSON your Partner for Automation and Control Page 005 of 052
1.2.1. An Innovative Leader in Global Markets

SAMSON is represented in more than 62 countries with more than 3,000 employees
worldwide and more than 45 subsidiaries worldwide with more than 100 engineering and
service centers worldwide.
SAMSON AG in Frankfurt is the headquarters for an international group of companies.
The mission is to offer customers across the world the best service possible as well as to
open up and develop new markets. Exporting SAMSON products and know-how plays
a key role. Design flexibility and customer proximity are crucial factors in SAMSON’s
success around the world.
Figure 1.2.1.-1: Prominent manufactures of special valves belong to the successful SAMSON GROUP
(See „Chapter 1.4 Production at SAMSON“)
SAMSON AG is one of the largest privately held control valve suppliers in the
world.
The basis for this success is the cooperation of the Research and Development, Design
and Production departments, practical engineering, and the continuous dialog with the
customer. Strict adherence to quality standards by the employees is also a prerequisite
for top efficiency and best quality resulting in the satisfaction of the customer.
SAMSON relies on experience gathered over almost a century. This wealth of information
forms a solid basis to provide solutions for any challenging application.
Factories using SAMSON equipment produce plastics, chemicals, pharmaceuticals,
food, petroleum products, and paper. SAMSON equipment air-conditions buildings
and distributes heat. Innovative SAMSON equipment is a fundamental component for
mechanical equipment and provides users with a competitive edge in the international
marketplace.

1.2.2. Market segments

Wherever there is flow to be controlled accurately, companies rely on SAMSON controls
and systems. SAMSON applies expert economical solutions based on its broad, proven
product line tailored to the specific applications.
The basis for this success is the cooperation of the Research and Development, Design
and Production departments, practical engineering and the continuous dialog with the
customer. Strict adherence to quality standards by the employees is also a prerequisite
for top efficiency and best quality resulting in the satisfaction of the customer. SAMSON
relies on experience gathered over almost a century. This wealth of information forms a
solid basis to provide solutions for any challenging application.
Application groups:
Biochemicals and Biofuels
Building automation (HVAC)
Conventional and Nuclear power stations
Cryogenic applications
Electrolysis
Energy, Utilities & Mining
Engineering & Construction
Fertilizer & Agrochemicals
Food, Beverages & Oleo chemicals
FPSO, FSO, FRSU and FRU
F = Floating, P = Production S = Storage, O = Offloading, R = Regasification, U = Unit
Gas Processes, Synthesis gas, Industrial & Specialty Gases

Health care
Inks, Dyes & Printing Supplies
LNG, LPG and GTL plants
Paints, Coatings & Resins
Petrochemicals Processes
Pharmaceuticals, Life sciences and Cosmetics
Plastics
Process automation
Pulp & Paper
Refineries and Refinery Processes
Solar thermal power plants
Steel Production
Textile industry

Research and Development at SAMSON Page 007 of 052
1.3 Research and Development at SAMSON

Any SAMSON product is developed in-house from the initial concept right through to the
production stage. SAMSON’s investment in R&D is considerably higher than the average
for the industry. The objective behind it being to develop products which are tailored to
the markets and offer extraordinary efficiency and value for money.
Figure 1.3.-1: SAMSON R & D

Test Bench and outdoor area
From the beginning of the design phase, SAMSON remains in constant contact with
the customer to ensure that the products are best suited to the practical applications.
Of similar importance is the cooperation with the production department and the field
engineers outside the company.

SAMSON combines mechanical and electric components to ensure that the products are
up to the control tasks of the future. SAMSON places prime importance on developing
reliable, easily maintainable and environmentally friendly products.
First floor
Ground floor
Basement
Figure 1.3.-2: Construction of test bench
Test benches
Test benches for durability tests
Several modular test benches
Fixed, automated valve test benches for following media:
Maximum data
Medium
DN Pressure Flow rate Temperature
Water 400 15 bar 1000 m3/h 50 °C
Air 250 10 bar 40 t/h 30 °C
Steam 200 13 bar 5 t/h 230 °C
Water / Steam 80 15 bar 90 m3/h 130 °C
Table 1.3.-3: Maximum data of test bench
The cavitation factor xFz introduced by SAMSON in 1973 is the basis for international
noise prediction standards and specifies at which pressure ratio cavitation starts. As a
result of a series 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 values to keep the valves free of vibration and cavitation
over the entire load range.

Figure 1.3.-4: Test bed facilities in the basement
Information
The equipment room provides several pumps with a total power of P = 240 kW, a total
pump flow rate of Q = 1000 m3/h, and a pump pressure of p = 15 bar each.
In addition, different shut-off and control valves control the process parameters for the
various test benches.
A compressor and desiccant air dryer dehumidify the air and compress it to a pressure of
p = 10 bar in the five tanks located outside the test lab building.
Packing test bench

Medium: Steam
Max. process data: p = 450 bar, T = 400°C
Areas of testing: Packing durability

Figure 1.3.-5: Test bench, First floor
Figure 1.3.-6: Test bench Water, Ground floor

Figure 1.3.-7: Test bench: Actuator dynamics, First floor
Figure 1.3.-8: Endurance bed test, First floor

1.3.1. Optimized device integration

SAMSON control valves can be integrated into all common process control systems. The
detailed functioning is demonstrated by the Smart Valve Integration Center (SVIC),
which was recently set up at the SAMSON headquarters in Frankfurt. At the Center, smart
valve assemblies can be integrated into commonly used control, engineering and asset
management systems to monitor their functioning while a process is running.
The center works in close cooperation with R&D and the test facilities department ensuring
all the requirements for optimal integration of smart SAMSON devices. An additional task
covered by the center involves the implementation of process or plant-specific setups in
laboratory conditions to optimize device technology or to monitor unique plant conditions
by performing individual system integration tests.
Figure 1.3.1.-1: SAMSON Smart Valve Integration Center (SVIC)
Device integration methods, such as EDDL and FDT/DTM, allow for vendor-independent
integration into process automation systems. Sound knowledge of widely used systems
and the performance of extensive system integration tests are necessary. The center,
therefore, functions as both training and test facility. Remote access to the systems
makes the center accessible from all over the globe. A powerful video and audio system
ensures unrestricted communication during training and support sessions.
Like the R&D test facilities, the center is at the heart of SAMSON’s research and
development activities. One of the main fields of activity entails research into new
technologies, such as wireless data transmission for diagnostics.

Additionally, studies of new technologies and methods for devices and diagnostics are
performed to provide end users with even more detailed condition monitoring of control
valves and to continuously reduce life cycle costs in the future. Further duties of the
Center include optimization of commissioning and initialization functions, including device
replacement, diagnostic functions, alarm management and handling, monitoring, long-
term tests as well as preparing certification tests.
To coincide with the opening of the Center, the SVIC Academy was launched. It offers
practice oriented training, e.g. advanced positioner training. This training focuses
on parameterization and configuration, diagnostic and status data logging as well as
servicing, replacing and commissioning SAMSON’s smart field devices. Additional
courses offered include basic training for HART®, PROFIBUS® PA and FOUNDATION
fieldbus™ networks. (See „Chapter 15. Interface to a control systems“
Figure 1.3.1.-2: SAMSON Smart Valve Integration Center (SVIC)
Far-sighted Monitoring Solutions

Analysis of diagnostic data – Asset management functions in digital positioners present
end users as well as SAMSON’s after-sales service with unprecedented opportunities
which were unachievable using analog technology. For example, statistical data provide
information on shifts in the working range of the valve, and the cycle counter shows the
load condition of the valve.

SAMSON’s digital positioners are increasingly used with on/off valves as they provide new
opportunities in combination with these valves as well, such as monitoring the opening
and closing times, the end positions and the availability of the valve by performing partial
or full stroke tests.
Integration of valve functions into process control and asset management systems –
End users value optimal valve performance to reduce life cycle costs as well as the fact
that the complete range of field device functions can be fully integrated into the control
system. This is accomplished by using standardized digital interfaces and protocols, such
as HART®, PROFIBUS® PA and FOUNDATION fieldbus™ as well as device integration
methods like FDT/DTM (Field Device Tool) and EDDL (Enhanced Device Description
Language) or, in the future, FDI (Field Device Integration).
When all specifications as well as requirements defined in NAMUR Recommendation
NE 105 are adhered to, all asset management and diagnostic functions of field devices,
including alarms specified in NAMUR Recommendation NE 107, can be put to full use.
Figure 1.3.1.-3: Far-sighted Monitoring Solutions

Production at SAMSON Page 015 of 052
1.4 Production at SAMSON

The ideas from research and development are turned into products by the SAMSON
manufacturing division to exceed customer requirements. One of the design criteria is the
modularity and interchangeability of standard SAMSON components. SAMSON offers a
great variety of modular products, for example, a standard valve series, available in seven
basic nominal sizes, offers 20,000 different combinations with individual characteristics.
Flexibility in accommodating specific customer requests and fast delivery give the
customer an additional advantage that has its roots in the SAMSON marketing strategy.
Due to detailed production planning and logistics, it has been possible to reduce the
production lead times to only a few weeks even for special product versions.
SAMSON has been continuously upgrading the manufacturing process to be more cost
effective and environmentally friendly. In addition while production time has been reduced,
product reliability continues to increase.
Figure 1.4.-1: Highly efficient CNC machining Centers with extremely accurate positioning make it pos-
sible to completely machine a valve body in a single set-up.
The computerized galvanizing process has a capacity of 9,000 components which pass
through 40 stations. The automatic priming process handles up to 10,000 kg (14,000 lbs)
per day. The resulting effluent passes through the company’s own treatment plant that
meets the most stringent government standards.
Equally high environmental standards are reached in the paint shop with its automatic
powder coating line. This process uses environmentally friendly epoxy and powder
coatings.

It is now standard practice at SAMSON that machining centers are used in the production
of valve bodies. Even valves with a nominal size of 500 (20”) can be handled completely
in this type of production center.
Figure 1.4.-2: An environmentally friendly electrostatic powder coating line guarantees, together with a
wet chemical primer, a consistent surface finish of the highest quality.
Product line at SAMSON

Self-operated regulators
Control valves for process engineering
Positioners,limit switches, accessories
Measuring and control equipment
Automation systems
Control valves for HVAC systems
Controllers and sensors for HVAC systems

Production at SAMSON Page 017 of 052
SAMSON GROUP production plants
SAMSON AG, Frankfurt (Headquarters) Germany
SAMSOMATIC GmbH, Frankfurt Germany
Pfeiffer Chemie - Armaturenbau GmbH, Kempen Germany
VETEC Ventiltechnik GmbH, Speyer Germany
LEUSCH GmbH Industriearmaturen, Neuss Germany
KT - Elektronik GmbH, Berlin Germany
SAMSON REGULATION S.A., Vaulx en Velin Cédex France
SAMSON PRODUCTS INC., Baytown, Texas USA
SAMSON CONTROLS PVT. LTD, District Pune

India
Maharashtra
SAMSON CONTROLS (CHINA) CO., LTD.

China
Beijing
SAMSON ÖLÇÜ ve OTOMATİK KONTROL SİSTEMLERİ

Turkey
SAN. ve TİC. A.Ş., Güneşli-İstanbul
AirTorque S.p.a., Albano Italy
Starline S.p.a., Bergamo Italy
Table 1.4.-3: SAMSON GROUP production plants

1.5 Quality assurance at SAMSON

Recognizing that investment in quality is the best investment possible, SAMSON’s primary
objective is to maintain the highest quality standards. Quality, as a symbol of excellence
in products and services, is the most important element of the SAMSON company policy.
Of primary importance is the total quality management system, which focuses all efforts
solely on the customer. In order to fulfill their expectations, a system of continuous quality
control has been established. It greatly exceeds checking the product specifications listed,
which is due to the individual competence, commitment and feeling of responsibility of
each employee. This system includes such diverse fields of operation as practical design,
incoming inspection, preventative maintenance, workplace safety and environmental
protection.
Figure 1.5.-1: CNC - controlled coordinate measuring machines with air cushion guidance and high
precision sensing test the tolerances of the work piece contours in all three dimensions.
SAMSON’s quality management system is modeled according to the international

standards ISO 9000 to 9004 and was certified already in 1990. This certification is
constantly monitored, both internally and externally, by auditing the entire process from
beginning to end. During these audits, the most modern measuring and testing methods
are used to ensure constant accuracy of results.
SAMSON employs, for example, CNC-driven three-dimensional coordinate measuring
systems in its quality control of materials and products.
In the material testing stage, state-of-the-art methods, such as spectral analysis,
ultrasound or surface crack detection are used. At the final testing stage of control valves,
computer-driven valve testing rigs are employed, which are specially developed for this
application by SAMSON and SAMSOMATIC.

Quality assurance at SAMSON Page 019 of 052
DIN EN ISO 9001:2000 Certificate

1.6 Logistic center and dispatch department
Figure 1.6.-1: Logistic center and dispatch department for worldwide delivery
The new center is the heart of a logistics system to further increase the availability of
SAMSON products. The logistics center combines the building complex in which the
dispatch department, the valve assembly department and the incoming inspection
department of SAMSON‘s quality assurance are placed.
The ability to manufacture 5,000 control valves at the headquarters each month is
achieved by keeping semi-finished
products and castings in stock to meet
unscheduled demands. 10 Rows of
shelves with 29 racks providing a total of
13,500 spaces for pallets and wire mesh
boxes.
The last stage that the control valves pass
on their way through the logistics center
is the sunlit final assembly hall. Here,
the painted components are assembled,
adjusted and checked to make sure the
final products comply with customer
specifications.
Figure 1.6.-2: Small parts storage in the logistics Center

SAMSON GROUP Page 021 of 052
1.7 SAMSON GROUP

SAMSON has formed affiliations with a series of companies also active in the field
of valve engineering, but specializing in the production of different valves from those
manufactured at SAMSON’s facilities. The specialization ranges from simple forged ball
valves to advanced bypass valves for steam turbines in nuclear power stations.
With the assistance of these associated companies, SAMSON is able to offer engineered
solutions from a single source to comply with the requirements of complex projects and
to meet unusual control challenges.
Figure 1.7.-1: SAMSON GROUP Logo
1.7.1. The associated companies
KT - Elektronik GmbH
Berlinickestrasse 11
12165 Berlin
Germany
www.kt-elektronik.de
KT Electronics has specialized in the production and development
of electronic micro controller-controlled devices.
The main use is the heating technology and building automation.

AIR TORQUE S.p.A.

Via Palazzo s.n.
24061 Albano S. Alessandro (Bergamo), Italy
http://www.airtorque.it
Founded in 1990
Pneumatic actuators Double acting and

with Rack and pinion Spring Return plus associated
design products.
Double acting
Double acting at 5.5 bar air Supply from 6,7 Nm to 4.955 Nm
Torque Ratings for at 80 psi air Supply from 59,1 LB-IN to 44.900 LB-IN
Standard Series 90° Spring Return models:
rotation Springs Torque from 3,4 Nm to 2.207 Nm
Springs Torque from 29,8 LB-IN to 19.350 LB-IN
Actuators with rotation 120° - 135° - 180°
180° Spring return actuators with 90° fail safety position
3 position and dosing actuators
Special actuators
Actuators with hydraulic speed control (damper)
Fast acting actuators
Forged stainless steel actuators double acting and spring return
Air Torque provides also a service for assembly-associated
Service components (switch boxes, positioners, solenoid valves, gear boxes,
brackets and couplings).

LEUSCH Industriearmaturen GmbH

Ziegeleistraße 10
41472 Neuss
Germany
www.leusch.de
Founded in 1974
Triple Excentric LTR 43:
NPS 3 to 80
Double Excentric LDE:
Butterfly Valves
NPS 20 to 80
Ball Valves
NPS 3 to 56
Rating ANSI Class 150 to 2500
Butterfly
Wafer; Lugged type;
Connection Butterfly and Ball valves
Flanged and Butt weld ends,
Top entry design with Butt weld ends
Stainless steel, carbon steel, special
Materials
alloys
Temperature Range -196 °C to +1000 °C
Thanks to his development of high-performance ball valves, segmented
ball valves as well as control and shut-off butterfly valves made of
various materials for temperatures ranging from –196 °C to +1000 °C
Note
and pressure ratings of up to PN 420 or ANSI Class 2500. The company
succeeded in fully establishing itself on the international market within
a few years.

Pfeiffer Chemie - Armaturenbau GmbH

Hooghe Weg 41
47906 Kempen
Germany
www.pfeiffer-armaturen.com
Founded in 1974
Valves with PTFE- or PFA– lining

Butterfly valves
Production Ranges Ball Valves
Sampling valves
Special valves
Pigging systems
Stainless steel, carbon steel, special

Materials
alloys
Temperature Range -40 °C to +250 °C
Specialist for valves with PTFE-lining, valves with PFA-lining, valves

of stainless-steel, and valves made of various steel-types.
Note Pfeiffer products are in service mainly in the chemical and

petrochemical industry, Gas Engineering Industry but are also
suitable for application in the Pharmaceutical Industry, Food Industry
and in the Processing of drinking water industries.

VETEC Ventiltechnik GmbH

Siemens-Str.. 12
67346 Speyer
Germany
www.vetec.de
Founded in 1901
Rotary Plug Valves

Production Ranges Actuators
Special models
Globe valves
Nominal size DN 25 to DN 500 / NPS 1 to NPS 20
Materials Cast steel / stainless cast steel steel
Temperature Range -100°C to 400°C / -148°F to 752°F
The VETEC rotary plug valve is an outstanding combination of a Dom
valve, butterfly valve, and the classic control valve and unifies all
their advantages such as free passage, no dead space, high gland
nut insularity, control over high pressure difference, compact design
and very good control properties. Rotary plug valves have a variety of
Note critical applications that can only be covered by conventional control
valves with difficulty.
From the oil and gas industry to petrochemical refineries and large-
scale chemistry, plant construction, the metal, paper or foodstuffs
industry: VETEC is The solution provider for controlling gas, steam,
liquid and solid flows.

STARLINE S.p.A.
Via F.Baracca, 30
24060 S. Paolo d’Argon (Bergamo)
Italy
www.starline.it
Founded in 1976
Forged Steel Ball Valves

Production Ranges
(Trunnion and Floating)

Nominal size NPS 1/4 up to NPS 8
A105 - LF2 - 304 - 304L - 316 - 316L
Materials
- F44 - F51 Monel and special materials.
Temperature Range -200° C +600° C
ASME B16.34
ASME B31.1
BS 5351
Standard Design API 6A (ISO 10423)
API 6D (ISO14313)
P.E.D. 97/23/EC
ATEX 94/9 CEl
The company also provides a service to assembly pneumatic,
Note hydraulic or electric actuators and all associated components for
remote control

SAMSOMATIC GMBH
Weismüllerstraße 20-22
60314 Frankfurt am Main
Germany
www.samsomatic.de
Founded in 1969, SAMSOMATIC on the SAMSON site
Solenoid valves
Limit switches
Transmitters
Service units
Production Ranges
Desuperheaters
Tank management systems
Size control systems
Tools correction systems
SAMSOMATIC GMBH has been own for innovative technology,

customer orientation, quality and reliability for over 40 years. Relying
Note on the know-how and experience of our staff, we provide technically
and economically viable solutions for process automation, building
automation and production engineering.

Product line summary of the SAMSON GROUP
Control Valves up to PN 40 (ANSI Class 300) and 450 °C (842 °F) for
Industrial Processes
Globe, Three-way and Angle Control Valves (Series 3240)
Globe and Three-way Control Valves (Series V2001)
Cryogenic, Diaphragm, Micro-flow and On-off Valves
Aseptic, Hygienic Valves, Sampling Valves, Pigging Systems
Butterfly Valves, Segmented Ball Valves,
Ball Valves and Rotary Plug Valves
Globe, Butterfly and Ball Valves with PTFE or PFA lining
Pneumatic actuators, pneumatic actuators with Rack and pinion design,
Double acting and Spring Return plus associated products
Control Valves up to PN 400 (ANSI Class 2500) and 550 °C (1022 °F)
for Industrial Processes
Globe, Three-way and Angle Control Valves (Series 3250)
Steam Converters (Series 3280), Desuperheaters
Spray Water Nozzle, Water bath desuperheater
Actuators
Control Valves up to PN 420 (ANSI Class 2500) and 1000 °C (1832 °F)
for Industrial Processes
High-performance control and shut-off Butterfly Valves,
High-performance Ball Valves and Segmented Ball Valves
Tailor-made solutions for industrial facilities
Control Valves for for conventional power stations

Special control valves
Hydraulic drive line Systems
Tailor-made solutions for industrial facilities
Positioners, Limit Switches, Accessories

Positioners
Limit Switches
Solenoid Valves
Booster
Accessories

Product line summary of the SAMSON GROUP
Self-Operated Regulators up to PN 40 (ANSI Class 300) and

-10 °C (14 °F) up to 350 °C (662 °F)
Temperature Regulators
Pressure Regulators
Differential Pressure and Flow Regulators
Boiler Regulators, Steam Traps, Air Vents, Strainers
Measuring and Control Equipment

Pneumatic and Electronic Controllers
Transmitters and additional Devices
Differential Pressure
Flow and Liquid Level Meters (Media)
Tank management system
Production engineering
Size control systems
Tool correction systems
Automation systems TROVIS 6600 and TROVIS MODULON

Modules and Software
Controllers and Sensors for Heating, Ventilation and

Air-conditioning (HVAC) Systems
Electronic Controllers and Control Systems
Sensors and Thermostats
Control Valves for HVAC Systems

Electric and Pneumatic Actuators
Control Valves
Control Valves with Jet Pump up to PN 25 (Class 250) and +220 °C ( 428 °F)
Combined Control Valves up to PN 40 (Class 300 and +150 °C ) (302 °F)

1.8 SAMSON’s Project execution

The success of our customers is also our success.
Successful enterprises must meet requirements which have increased steadily in the past
and will increase further in the future. Not least by the increasing location competition in
the course of the globalization.
The enterprises in the process industry demand an optimal use of their plants at a
simultaneous increase of the quality of the products. Therefore it demands a complete
technical and economic planning of its plants or plant sections from a hand.
Figure 1.8.-1: Your projects belong into safe hands.
An exact control valve choice requires long-standing experience and detail technology
with competence.
Therefore we have next to our worldwide 45 subsidiaries and more than 100 engineer
and sales offices internationally experienced engineers combined in a central project
department.
Customer staff can take advantage of
SAMSON`s hands-on training courses
to acquire state-of-the-art knowledge
essential for the safe, trouble free
operation of your plant.
It is for the enterprises all about an

efficiency of its production plants
permanently growing, particularly:
Higher productivity,
Higher flexibility,
Improves utilization of plant capacity,
Improves quality,
Cost reduction.
Figure 1.8.-2: Hands-on training

Extract of reference installations Page 031 of 052
1.9 Extract of reference installations

Factories using SAMSON equipment produce plastics, chemicals, pharmaceuticals,
food, petroleum products, and paper. SAMSON equipment air-conditions buildings
and distributes heat. Innovative SAMSON equipment is a fundamental component for
mechanical equipment and provides users with a competitive edge in the international
marketplace.
Petrochemical plant: Steam Cracker
Photo BASF
Capacity 600,000 t/year Ethylene, 400,000 t/year Propylene and further by-products.
Company Linde AG is an international technology group comprising
Contractor three Business Segments: Gas and Engineering, Material Handling and
Refrigeration.
In Europe, BASF has another important Verbund site in Antwerp, Belgium.
At this highly integrated site, BASF produces in addition to Ludwigshafen,
End user
petrochemicals from the Steam Cracker, numerous chemicals as well as
fertilizers, plastics and fibre products in some 54 plants.
Location The Antwerp region is the world’s second largest petrochemicals Center.
1993 and BASF extended the capacity hers naphtha steam cracker on
Commissioning
1.08 million tons of ethylene per annum in the year 2007.
Order 752 Valves were installed by the SAMSON GROUP in this plant.

Refinery
Photo Shell
1.8 Million tons Oil per Year
Capacity A wholly owned integrated refinery complex with an ethylene
cracker and an aromatics extraction unit.
Contractor Linde AG and LURGI Oil Gas Chemicals, Germany
A joint venture in Germany, between the oil refining and marketing

businesses of Shell and Germany’s DEA, has resulted in a signifi-
cant increase in the volume of base petrochemicals marketed by
Business Activities Shell chemicals companies in Europe. As part of the deal they will
take over responsibility for the sales and marketing of principally
lower olefins and aromatics products from the joint venture’s inte-
grated refinery and petrochemical complexes.
Licensor UOP LLC, headquartered in Des Plaines, Illinois, USA
End user Shell & DEA Oil GmbH
Location Heide, Germany
Commissioning 2000
490 Valves with DN 1” to 12” ANSI Class 150 to Class 2500 and
Order PROFIBUS Positioners were installed by the SAMSON GROUP in
this plant.

Petrochemicals production plants
Photo BASF
Ethylene 600,000;
Polyethylene (LDPE) 400,000;
Aromatic compounds 300,000;
Ethylene oxide/Ethylene glycol 300,000;
C4 Oxo-alcohols 250,000;
Capacity Acrylates 215,000;
(metric tons per year): Acrylic acid 160,000;
Formic acid 40,000;
Dimethylformamide 40,000;
Methylamine 36,000 as well as
Propionic acid 30,000.
In total 1.7 million metric tons of products leave the plant every year.
Contractor BASF-YPC Company Ltd., Nanjing, PR China
End user BASF Verbund Site Nanjing
Location Nanjing, PR China
Commissioning 2005
Order HART Positioners were installed by the SAMSON GROUP in this
plant.

Petrochemical Complex
Photo Sinopec Engineering Inc., China

550,000 tpa styrene monomer
250,000 tpa propylene oxide
320,000 tpa mono-ethylene glycol
60,000 tpa mono propylene glycol
Capacity
135,000 tpa Polyols
240,000 tpa polypropylene
200,000 tpa LLDPE and HDPE
250,000 tpa LDPE Low density polyethylene
The largest Sino-foreign investment in China between Chinese
Contractor
National Offshore Oil Company (CNOOC) and Shell Nanhai B.V.
As project management contractor, BSF
Project management Bechtel, San Francisco, USA,
contractor Sinopec Engineering Inc., China
Foster Wheeler Energy Ltd., UK
Chinese National Offshore Oil Company (CNOOC) and Shell Pet-
rochemicals Company Ltd. (CSPC), a joint venture of Shell Nanhai
End user
B.V., with 50 percent share holding, and CNOOC Petrochemicals
Investment Ltd. (CPIL) also with 50 percent.
Location Nanhai, PR China
Commissioning 2004/2005
571 Valves with DN 1” to 60” ANSI Class 150 to Class 2500 were
Order
installed by the SAMSON GROUP in this plant.

Petrochemical plant: Ethan Cracker
Photo CHEMIEREPORT.at
1.5 million t/y ethane
The steamcracker with an ethylene capacity of approximately 1.5
million tonnes per year is based on ethane feedstock and will be
Capacity
the heart of a petrochemical complex, located in Ruwais in the
United Arab Emirates, producing polyethylene and polypropylene
for export.
Contractor The Linde Group

Borouge is a joint venture between the Abu Dhabi National Oil
End user
Company (ADNOC) and Borealis
Location Ruwais, United Arab Emirates
Commissioning 2010 (currently under construction)
Order HART Positioners were installed by the SAMSON GROUP in this
plant.

Chemical production plants
Photo BASF
Different chemical production plants.
Segment structure of BASF:
Chemicals
Plastics
Capacity
Performance Products
Functional Solutions
Agricultural Solutions
Oil & Gas
Contractor The BASF Group and other engineering companies
BASF is the world’s leading chemical company –
End user The Chemical Company. With about 97,000 employees we serve
customers and partners in almost all countries of the world.
Location Headquarters of the BASF Group, Ludwigshafen, Germany
Commissioning Depending on completion of the plants within the last few years.
About 35,000 SAMSON valves in all sizes and series as well as
Order for the most different media are in use in the plant Ludwigshafen,
Germany.

Chemical production plants
Photo BASF
Different chemical production plants.
At, Belgium, BASF produces a wide variety of petrochemicals,
inorganics, fertilizers, intermediates, specialty chemicals, styrene
polymers, polyurethanes, super absorbents and dispersions. The
steam cracker provides the Verbund site with a stable supply of raw
Capacity
materials.
In 2004, BASF began operating its new world-scale plant for the
plastic ABS at its Antwerp production site. The plant has an annual
capacity of 200,000 metric tons. BASF is the world’s leading
chemical company.
Contractor The BASF Group and other engineering companies
BASF is the world’s leading chemical company –
End user The Chemical Company. With about 97,000 employees we serve
customers and partners in almost all countries of the world.
Location Antwerp, Belgium
Commissioning Depending on completion of the plants within the last few years.
About 7000 control valves are in the BASF Verbund Site Antwerp,
Order
Belgium for all sorts of applications in use.

Methanol plant
Photo China BlueChemical Ltd.

2,000 tonnes of methanol per day from natural gas. With a
designed annual production capacity of 600,000 tonne/year, the
CNOOC Jiantao methanol plant is one of the largest single facilities
of its kind in China. Located in the Dongfang City of Hainan
Capacity province.
The methanol plant utilizes the equipment and technology of
the German Lurgi Group, uses natural gas as raw material. It is
equipped with advanced technology, the energy consumption is low
and the operation is environmental-friendly and clean.
Contractor Lurgi AG, Frankfurt, Germany
China BlueChemcial Ltd., Dongfang.
CNOOC Jiantao is a joint venture between China BlueChem and
End user
a subsidiary of Kingboard Chemical Holdings Limited (“Kingboard”,
HKSE code: 0148.HK), with interests of 60% and 40% respectively.
Location Dongfang of Hainan province, PR China
Commissioning 2006
About 87 control valves with DN 1” to 12” ANSI Class 150 to Class
Order 2500 and PROFIBUS Positioners were installed by the SAMSON
GROUP in this plant.

Floating Storage and Re-gasification Unit (FSRU)
Photo Foto de: Julio Guedes

The storage capacity of Golar Spirit is 129,000 m3 LNG.
Capacity The re-gas capacity is 7,000,000 m3/d (250,000,000 cu ft/d) of gas,
equivalent to approx. 5,300 tons of LNG per day.
Contractor Sovereign Spirit Limited, a subsidiary of Golar LNG
Golar Spirit was chartered by Petrobras in Brazil in April 2007 for a
ten-year charter as an FSRU (Floating Storage and Re-gasification
Unit) commencing summer 2008.
After conversion and successful gas trials and commissioning of
End user
the Pecém Terminal in Brazil she relocated to Guanabara Bay, Rio
de Janeiro. Here she commissioned Brazil’s second LNG import
facility, which is a sea island inside the well protected Guanabara
Bay.
Location Guanabara Bay, Brazil
Commissioning 2008
Order 52 Valves were installed by the SAMSON GROUP in this FSRU.
Golar Spirit is also the world’s first permanently located re-gas
Note
vessel.

Biodiesel and Glycerine Plant
Photo Lurgi AG
200,000 tonnes/year
Special Features
Capacity Continuous Transesterification Process
Multifeedstock: Rape, Sunflower
Oil Refining, Winterization, Bleaching, Glycerine
Contractor Lurgi AG, Germany
Licensor Lurgi AG, Frankfurt, Germany
End user Natural Energy West GmbH (NEW)
Location Marl, Germany
Commissioning 2005
Order 49 Valves were installed by the SAMSON GROUP in this plant.
Note Largest biodiesel plant in Germany

Pharmaceutical processing plant
Photo Roche
Application Biochemical
Contractor Sartorius BBI Systems
End user Roche Diagnostics GmbH Penzberg, GERMANY
Location Penzberg, Germany
Commissioning 2005
59 Valves with PROFIBUS positioners were installed by the SAM-
Order
SON GROUP in this plant.
Type 3249-7 Type 3241-7 Type 3247-7

Forged steel

HVAC: Swiss Re Building
Swiss Re Building
http://upload.wikimedia.org/wikipedia/commons/c/cb/Swissre.and.
Photo
tower42.london.arp.jpg
Building The Correct Hydraulic Solutions for Swiss Re, London
The SAMSON differential pressure controllers enabled balancing
Application of the system, and good authority to be provided for the 2-port
motorized temperature control valves.
Order 87 SAMSON delivered Differential Pressure and Flow Regulators.
M
M
M
M
M
M
M
Figure 1.9.-1: Application for hydraulic balancing

Solar Thermal Power Generation Plant
Application Vapor, Thermal oil and Molten salt application

Contractor COBRA and SENER
Project - Location EXTRESOL SOLAR HEATING PLANT, Spain
124 Valves were installed by the SAMSON
Order
GROUP in this 50 MWe solar heating plants.
The above diagram shows a typical solar thermal power plant.

1. Parabolic mirrors gather energy for the heat transfer fluid.
2. Hot fluid returns from the solar field. Heated transfer fluid is moved
to the boiler or to the storage tank heat exchanger.
3. The hot fluid transfers its heat energy to water, creating steam.
4. Steam is used to drive a turbine, creating electricity.
5. Energy is stored in the hot and cold storage tanks.
6. The transfer fluid is recirculated to the collection field to absorb
more solar energy.

1.10 Subsidiaries and Engineer and Sales Offices of SAMSON GROUP

SAMSON in Europe
SAMSON worldwide
Subsidiary
Subsidiary with production
Branch office
See further addresses for Germany, Europe and Worldwide under http://www.samson.de

Subsidiaries and Engineer and Sales Offices of SAMSON GROUP Page 045 of 052
1.10.1. Extract of the subsidiaries

With 45 mostly independent subsidiaries in 62 countries worldwide and over 100
representatives or sales offices, SAMSON is on hand to provide local customer service
all over the world.
Highly trained personnel carry out assembly and service work on site. A well-tuned logistics
system assures delivery on time. Production facilities, which develop and produce special
products for regional markets, are located in several European countries as well as in
Japan, China, India and the United States.
SAMSON is on hand to provide local customer service all over the world, with:
Our warehouses carry a comprehensive inventory

Warehouse of control valves, regulators and accessories to
meet the needs of our customers.
Our work shops are fully-equipped and staffed with

Shop highly trained technicians for assembly, testing and
repair of our complete line of products.
We are continually offering training seminars for all

Seminars
our representatives and customers.
Assistance on regional and global service

agreements. Assisting subsidiaries with equipping
After sales service workshops with conventional tools, special tools,
and test rigs. Training of workshop and service
personnels.
You’ll find updates for SAMSON’S electronic
product’s, including the SAMSON valve sizing
Support &
program, Trovis View, Trovis Expert, as well as
Downloads
device description files for the Foundation Fieldbus
and Profibus positioners.
An example of SAMSON’s international presence is the North American subsidiary located
in the world’s largest petrochemical center in Houston, Texas. On almost 5,000 square
meters, SAMSON Controls Inc. stocks common products and assembles control valves
and regulators for customers in the chemical, petrochemical, pulp and paper, HVAC, and
food and beverage industries. For professional advice, two highly qualified teams and
their representatives provide responsive support for North America.
Here, as anywhere in the world, SAMSON continues to prove that the cooperation of a
central head office and a network of subsidiaries maximize the efficiency and strengths of
the entire group. This allows combination of all innovative and ambitious developments
into a successful unit which meets customer demands.

SAMSON CONTROLS INC., Markham, Ontario, Canada
SAMSON CONTROLS INC. in Baytown, Texas, USA

SAMSON CONTROL LTDA., Centro Empresarial Capuava Bairro Moinho Velho,

COTIA / SP, Brazil
SAMSON Control LTDA., Santiago, Chile

SAMSON REGULATION S.A., Vaulx en Velin Cédex, France
SAMSON ÖLÇÜ VE OTOMATİK KONTROL SİSTEMLERİ SAN. VE TİC. A.Ş.

Günesli-İstanbul, Turkey

SAMSON CONTROLS PVT. LTD., Maharashtra, District Pune, India
SAMSON CONTROLS (CHINA) CO., LTD., Beijing, PR China

SAMSON CONTROLS PTE LTD, Singapore
SAMSON CONTROLS PTY LTD, Matraville, Australia

Optimally engineered products

SAMSON’s expertise in control valve engineering covers all processes in industrial plants.
Extensive experience gained over the past years from the design, development, and
manufacture of custom-engineered solutions serves as the basis for mastering new
challenges. The wide range of products proven in practice can be customized in close
cooperation with the customer to provide a commercially acceptable solution to meet the
requirements of even the most complex applications.
Figure 1.10.1.-1: Valve engineering from one source


Chapter 1 Introduction

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Chapter 1 Introduction

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Table of contents

1.1.2. Scope of topics �����������������������������������������������������������������������������������������002

1.1.3. How to use this book? �������������������������������������������������������������������������������003

1.1.4. Structure and sequence ����������������������������������������������������������������������������003

1.2 SAMSON your Partner for Automation and Control ��������������������������������������004

1.2.1. An Innovative Leader in Global Markets ��������������������������������������������������005

1.2.2. Market segments ��������������������������������������������������������������������������������������006

1.3 Research and Development at SAMSON �������������������������������������������������������007

1.3.1. Optimized device integration ��������������������������������������������������������������������� 012

1.4 Production at SAMSON ������������������������������������������������������������������������������������015

1.5 Quality assurance at SAMSON ������������������������������������������������������������������������018

1.6 Logistic center and dispatch department ������������������������������������������������������020

1.7.1. The associated companies ������������������������������������������������������������������������ 021

1.8 SAMSON’s Project execution �������������������������������������������������������������������������030

1.9 Extract of reference installations ��������������������������������������������������������������������031

1.10 Subsidiaries and Engineer and Sales Offices of SAMSON GROUP ����������044

1.10.1. Extract of the subsidiaries �����������������������������������������������������������������������045

SAMSON AG · MESS- UND REGELTECHNIK · Weismüllerstraße 3 · 60314 Frankfurt am Main · Germany

Figure 1.1.-1: Process monitoring system of brewery Beck´s

SAMSON AG · MESS- UND REGELTECHNIK · Weismüllerstraße 3 · 60314 Frankfurt am Main · Germany

1.1.2. Scope of topics

SAMSON AG · MESS- UND REGELTECHNIK · Weismüllerstraße 3 · 60314 Frankfurt am Main · Germany

1.1.3. How to use this book?

1.1.4. Structure and sequence

For the reader who has to work on a special problem:

SAMSON AG · MESS- UND REGELTECHNIK · Weismüllerstraße 3 · 60314 Frankfurt am Main · Germany

1.2 SAMSON your Partner for Automation and Control

SAMSON AG · MESS- UND REGELTECHNIK · Weismüllerstraße 3 · 60314 Frankfurt am Main · Germany

1.2.1. An Innovative Leader in Global Markets

SAMSON AG · MESS- UND REGELTECHNIK · Weismüllerstraße 3 · 60314 Frankfurt am Main · Germany

1.2.2. Market segments

 Gas Processes, Synthesis gas, Industrial & Specialty Gases

SAMSON AG · MESS- UND REGELTECHNIK · Weismüllerstraße 3 · 60314 Frankfurt am Main · Germany

1.3 Research and Development at SAMSON

Figure 1.3.-1: SAMSON R & D

SAMSON AG · MESS- UND REGELTECHNIK · Weismüllerstraße 3 · 60314 Frankfurt am Main · Germany

Figure 1.3.-2: Construction of test bench

SAMSON AG · MESS- UND REGELTECHNIK · Weismüllerstraße 3 · 60314 Frankfurt am Main · Germany

Figure 1.3.-4: Test bed facilities in the basement

Packing test bench

SAMSON AG · MESS- UND REGELTECHNIK · Weismüllerstraße 3 · 60314 Frankfurt am Main · Germany

Figure 1.3.-5: Test bench, First floor

Figure 1.3.-6: Test bench Water, Ground floor

SAMSON AG · MESS- UND REGELTECHNIK · Weismüllerstraße 3 · 60314 Frankfurt am Main · Germany

Figure 1.3.-7: Test bench: Actuator dynamics, First floor

Figure 1.3.-8: Endurance bed test, First floor

SAMSON AG · MESS- UND REGELTECHNIK · Weismüllerstraße 3 · 60314 Frankfurt am Main · Germany

1.3.1. Optimized device integration

Figure 1.3.1.-1: SAMSON Smart Valve Integration Center (SVIC)

SAMSON AG · MESS- UND REGELTECHNIK · Weismüllerstraße 3 · 60314 Frankfurt am Main · Germany

Figure 1.3.1.-2: SAMSON Smart Valve Integration Center (SVIC)

Far-sighted Monitoring Solutions

SAMSON AG · MESS- UND REGELTECHNIK · Weismüllerstraße 3 · 60314 Frankfurt am Main · Germany

Figure 1.3.1.-3: Far-sighted Monitoring Solutions

SAMSON AG · MESS- UND REGELTECHNIK · Weismüllerstraße 3 · 60314 Frankfurt am Main · Germany

1.4 Production at SAMSON

SAMSON AG · MESS- UND REGELTECHNIK · Weismüllerstraße 3 · 60314 Frankfurt am Main · Germany

Product line at SAMSON

SAMSON AG · MESS- UND REGELTECHNIK · Weismüllerstraße 3 · 60314 Frankfurt am Main · Germany

SAMSON GROUP production plants

SAMSON AG, Frankfurt (Headquarters) Germany

SAMSOMATIC GmbH, Frankfurt Germany

Pfeiffer Chemie - Armaturenbau GmbH, Kempen Germany

VETEC Ventiltechnik GmbH, Speyer Germany

1.1.2. Scope of topics ��002

1.1.3. How to use this book? ��003

1.1.4. Structure and sequence ��003

1.2 SAMSON your Partner for Automation and Control ��004

1.2.1. An Innovative Leader in Global Markets ��005

1.2.2. Market segments ��006

1.3 Research and Development at SAMSON ��007

1.3.1. Optimized device integration �� 012

1.4 Production at SAMSON ��015

1.5 Quality assurance at SAMSON ��018

1.6 Logistic center and dispatch department ��020

1.7.1. The associated companies �� 021

1.8 SAMSON’s Project execution ��030

1.9 Extract of reference installations ��031

1.10 Subsidiaries and Engineer and Sales Offices of SAMSON GROUP ��044

1.10.1. Extract of the subsidiaries ��045

Gas Processes, Synthesis gas, Industrial & Specialty Gases

Pneumatic actuators Double acting and

Valves with PTFE- or PFA– lining

Rotary Plug Valves