Mounting and Operating Instructions EB 8093 EN
Contents
1. Fig 6 Packing Note There is no guide bushing in valve sizes NPS 4 and 6 Class 150 and 300 with reduced overall height 6 Apply lubricant order no 8150 0116 to the plug stem thread of the new or original plug that has been machined Screw guide bushing 24 onto the bel lows stem as far as it will go Lock into position with the nut 35 or slide on the guide bushing and fasten with two nuts Replace old washers 30 with new ones Screw the plug stem tightly into the bel lows stem Tightening torque 50 Nm for DN 25 to 80 NPS 1 to 3 140 Nm for DN 100 to 150 NPS 4 to 6 Seat If the seat must also be replaced proceed as follows 9 Use a SAMSON seat wrench to unscrew the seat 4 out of the valve body 10 Apply lubricant order no 8150 0116 to the seat thread of the new seat and Maintenance screw in tightly observing the tightening torques in Table 1 Assembly l Slide bellows stem together with metal bellows 37 guide bushing 24 and plug into the body Insert bellows nut 41 and screw tight Screw spacer stem onto the bellows stem observing tightening torques in Table 1 Insert new gasket 17 into the flanged section Slide valve bonnet over the spacer stem and place it on the flanged section Thread on nut 33 and screw tight ob serving the tightening torques in Table 1 Apply lubricant order no 8150 01 16 to packing part2. Lift the actuator A 1 off the valve Mounting the actuator 1 Loosen the lock nut 10 and stem con nector nut 9 on the valve Firmly press the plug 5 with the plug stem into the seat 4 Then thread down the lock nut and stem connector nut 2 Remove clamps of the stem connector A 51 and annular nut A 9 on the ac tuator A 1 3 Slide the annular nut over the spacer stem 71 4 Place the actuator on the valve bonnet 2 and screw tight using the annular nut A 9 5 Read the nameplate on the actuator to determine which bench range signal range with pretensioned springs and which fail safe are used The fail safe action Actuator stem extends or Actuator stem retracts is indicated on the nameplate by FA or FE respectively on the Type 3271 Actuator and by the appro priate symbol on the Type 3277 Actuator The lower bench range corresponds to the lower signal pressure range to be adjusted while the upper bench range corresponds to the upper signal pressure range 6 For actuators with fail safe action Actu ator stem extends apply the pressure corresponding to the lower signal pres sure range e g 0 2 bar to the loading pressure connection on the bottom dia phragm chamber For actuators with fail safe action Actu ator stem retracts apply the pressure corresponding to the upper signal pres sure range e g 1 bar to the loading pressure connection on the top dia phragm chamber 7 Th
3. A 5 Stem connector Fig 4 Type 3248 1 Type 3248 Globe Valve with Type 3271 Pneumatic Actuator EB 8093 5 Assembling and adjusting valve and actuator Fail safe position Depending on how the springs are arranged in the actuator the control valve assumes one of two different fail safe positions Actuator stem extends When the pressure is relieved or the supply air fails the actuator springs move the actu ator stem downwards and close the valve Actuator stem retracts When the pressure is relieved or the supply air fails the actuator springs move the actu ator stem upwards and open the valve Fig 5 Valve bonnet with yoke PN 100 Class 600 6 8093 EN 2 Assembling and adjusting valve and actuator If the valve and actuator have not been pre assembled by the manufacturer or in the case that the original actuator attached to the valve is to be replaced by another actua tor of a different type or size proceed as follows Removing a mounted actuator Note For actuators with fail safe action Actuator stem extends and especially actuators with pretensioned springs apply a pressure slightly higher than the lower bench range see actuator nameplate to the loading pressure connection on the bottom diaphragm chamber before undoing the annular nut A 9 Remove clamps of the stem connector A 51 between the actuator stem and spacer stem and unscrew annular nut A 9
4. 8310 EN for Type 3271 EB 8311 EN for Type 3277 5 Maintenance If leakage occurs this could be caused by a damaged metal bellows 37 or a defective packing 15 If the valve does not seal properly the tight shut off may be impeded by dirt or other im purities caught between the seat and plug or by damaged facings Remove the parts clean them thoroughly and replace them with new ones if neces sary Before servicing or disassembling the control valve depressurize the rele vant section of the plant and drain it Wait until the medium has reached ambient temperature if necessary As valves are not free of cavities there might still be residual medium in the valve We recommend removing the valve from the pipeline or the entire valve assembly when the valve is welded in the pipeline On performing any work on the valve body first shut off the supply pressure disconnect the supply pres sure line and remove the actuator Operation Note Seat wrenches can be ordered using the following order numbers For DN 15 to 150 Complete set 1280 3047 For DN 15 and 25 Single set 1280 3073 EB 8093EN 9 Maintenance 5 1 Replacing packing seat and plug Removing the actuator Prior to performing any work on the valve body remove the actuator first Note For actuators with fail safe action Actuator stem extends and especially actuators with pretensioned springs apply a pressure slightly
5. Pneumatic Control Valves Type 3248 1 and Type 3248 7 Fig 1 Type 3248 as globe valve and angle valve both with Type 3277 Pneumatic Actuator Mounting and Operating Instructions EB 8093 EN C Edition December 2010 Contents Contents 1 2 24 Note Page Design and principle A Assembling and adjusting valve and actuator 2 2 6 Option to pretension the springs for actuator version Actuator stem extends 2 Valve and actuator that have different rated travels 2 8 Installation 2222 22 Coon 8 Mounting 8 Signal pressure line 8 Operation o wow X Romeo 499 P 9 vow VOX ine wo 9 7 Replacing packing seat and plug 10 Protective cover 12 Customer inquiries 14 Non electrical actuators and valves do not have their own potential ignition source according to the risk assessment in the rare incident of an operating fault corresponding to EN 13463 1 2001 paragraph 5 2 and therefore do not fall within the scope of the European Directive 94 9 EC Refer to paragraph 6 3 of EN 60079 14 1977 VDE 0165 Part 1 concerning connection to the equipotential bonding system 2 EB 8093 EN Safety instructions General safety instructions The control valve must only be mounted started up or serviced by fully trained an
6. allow the control valve to cool down or warm up to reach ambient temperature prior to starting any work on the valve Prior to performing any work on the valve make sure the supply air and control signal are disconnected or blocked to prevent any hazards that could be caused by moving parts Special care is needed for pneumatic control valves when the actuator springs are pretensioned These actuators are labeled correspondingly and can also be identified by three long bolts protruding from the bottom of the actuator Prior to starting any work on the control valve relieve the compression from the pretensioned springs 8093 3 Design and principle of operation 1 Design and principle of operation The Type 3248 Cryogenic Valve can be combined with either a Type 3271 or a Type 3277 Pneumatic Actuator with integral positioner attachment The globe pattern or angle pattern valve body is designed for welding in vacuum in sulated pipelines or for installation in cold box applications The cryogenic exten sion bonnet consists of a metal bellows lo cated directly above the valve body and the insulating section above the bellows seal The test connection 42 allows the pressure to be monitored in order to check the metal bellows for leakage The process medium flows through the valve in the direction indicated by the arrow The position of the plug 5 is determined by changes in the signal pressure acting on the actu
7. ator diaphragm The plug stem extension consists of a spacer stem 71 and bellows stem 37 The stem extension is connected by the stem connec tor A 51 to the actuator stem A 7 The plug stem is sealed by the metal bellows and the backup packing 15 with spring loaded PTFE carbon V ring packing Fig 6 Fig 2 Type 3248 as angle valve in aluminum T SI LJ RU Pr LI D Fig 3 Valve bonnet with Type 3277 Actuator EB8093 EN Design and principle of operation 37 Bellows stem with metal bellows T A1 Legend PN 9 1 Valve body DOSS 1 2 Cryogenic extension bonnet 71 A51 2 Valve bonnet EX A Seat q 84 gt 5 Plug NS 2 i ix 8 Threaded bushing 32 ER 9 9 connector nut 33 7 10 10 Lock nut 95 9 IS 8 15 Packing 95 TT KN 15 17 Gasket II 17 24 Guide bushing N N Caz 42 ashers i l 43 32 Studs Sm 33 Nuts for studs 71 35 Nut for guide bushing 37 2 Seal for metal sealing Al Bellows nut 42 Test connection 43 Flat gasket 41 71 37 2 SS N Spacer stem 4 84 Travel scale indicator 95 Protective cover rs 30 95 2 Adjustment bolt for protective cover 2 1 2 95 9 Spacer sleeve washer 7 35 rmm 24 Actuator HT NO 5 A 7 Actuator stem we 4 A 9 Annular ring
8. bolts protruding from the bottom di aphragm case which allow the spring com pression to be unloaded evenly before re moving the actuator from the valve 8 EB 8093 EN 3 Installation 3 1 Mounting position The valve can be mounted in any position It must be installed free of tension If necessary supports can be mounted on the pipelines near the connections If an actuator with a side mounted handwheel is installed at an angle less than 45 to the horizontal the actuator must be additionally supported CAUTION Prior to welding the valve body into the pipeline apply air pressure for valves with fail safe action Actuator stem extends valve closed to move the valve plug out of the seat This prevents the trim from being damaged by excessive high temperatures Note Remove the stopper from the test connection 42 to allow the metal bellows 37 to be monitored for leakage 3 2 Signal pressure line Connect the signal pressure line for valves with fail safe action Actuator stem extends to the loading pressure connection on the bottom diaphragm case and for valves with fail safe action Actuator stem retracts to the loading pressure connection on the top diaphragm case The lower connection of Type 3277 Actuator is located on the yoke at the bottom dia phragm case 4 Operation To reverse the direction of action refer to Mounting and Operating Instructions of the respective pneumatic actuator EB
9. d qualified personnel observing the accepted industry codes and practices Make sure employees or third persons are not exposed to any danger All safety instructions and warnings in these mounting and operating instructions particularly those concerning assembly start up and maintenance must be observed The control valves fulfill the requirements of the European Pressure Equipment Directive 97 23 EC Valves with a CE marking have a declaration of conformity that includes information about the applied conformity assessment procedure The corresponding declaration of conformity can be viewed and downloaded on the Internet at http www samson de For appropriate operation make sure that the control valve is only used in areas where the operating pressure and temperatures do not exceed the operating values which are based on the valve sizing data submitted in the order The manufacturer does not assume any responsibility for damage caused by external forces or any other external influence Any hazards which could be caused in the control valve by the process medium operating pressure signal pressure or by moving parts are to be prevented by means of the appropriate measures Proper shipping and appropriate storage of the control valve are assumed CAUTION For installation and maintenance work on the valve make sure the relevant section of the pipeline is depressurized and depending on the process medium drained as well If necessary
10. higher than the lower bench range see actuator nameplate to the loading pressure connection on the bottom diaphragm chamber before undoing the annular nut A 9 1 Remove clamps of the stem connector A 51 between actuator stem and spacer stem and unscrew annular nut A 9 2 Lift the actuator off the valve Packing Fig 6 1 Unscrew the stem connector nut 9 and lock nut 10 2 Undo threaded bushing 8 to relieve the tension from the packing 15 3 Unthread the nuts 33 at the valve bon net Lift valve bonnet upwards off the flanged section of the cryogenic exten sion bonnet 1 2 4 Unthread threaded bushing 8 and use a suitable tool to remove the packing 15 including the packing rings 16 10 8093 EN washer 12 and spring 11 Replace damaged parts with new ones Carefully clean the packing chamber Plug 1 Unscrew spacer stem 71 2 Use a SAMSON socket wrench to unscrew the bellows nut 41 Pull out the bellows stem together with the metal bel lows 37 guide bushing 24 and plug 5 from the cryogenic extension bonnet 1 2 3 Use a suitable tool to clamp the bellows stem 37 tightly 4 Unthread the plug from the bellows stem 5 Loosen nut 35 Unscrew guide bushing 24 In the case of large nominal sizes unscrew second nut and remove guide bushing 5 IRSKA T y TEE PSST PRE NP z SN IRQ KISS
11. ion 2 2 Detach the spacer stem 71 from the bellows stem 37 by unscrewing the stem connector nut and lock nut 3 Remove the nuts 33 on the valve bon net Carefully lift off the valve bonnet 2 including the spacer stem from the flanged section of the cryogenic exten sion bonnet 1 2 4 Align the protective cover with stuck on O ring 95 7 onto the studs 32 5 Place the protective cover with adjust ment bolt 95 2 on the thread of the bel lows stem 37 6 Turn the adjustment bolt SW 19 clock wise until the protective cover 95 1 is seated on the flange 8 Fasten tight the studs 32 with nuts 33 and spacer sleeves washers 95 9 Protective cover Removing the protective cover 1 Remove the nuts 33 and wash ers spacer sleeves 95 9 2 Turn the adjustment bolt 95 2 counter clockwise The plug is lowered and the protective cover is lifted off the flange 3 After reaching the threaded end of the bellows stem 37 remove the protective cover A Use the nuts 33 to mount the actuator The washers spacer sleeves 95 9 are no longer required Mounting the valve bonnet with spacer stem 1 Insert a new gasket 17 into the body flange 2 Place the valve bonnet 2 with spacer stem 71 onto the body flange To do so place the spacer stem over the thread of the bellows stem 37 and hand tighten While doing so do not change the position of the stem connector nut 9 or the l
12. ock nut 10 on the spacer stem 3 Tighten the nuts 33 on the studs 32 in a criss cross pattern using the torque listed in Table 1 4 Use the stem connector nut 9 to fasten tight the spacer stem 71 and the bel lows stem 37 using the torque listed in Table 1 5 Check whether the threaded bushing 8 is tightened as far as it will go 6 Mount the actuator If the position of the stem connector nut and lock nut has not changed while the 8093 13 Customer inquiries valve bonnet was removed the bench range is still correct and does not need to re adjusted When the stem connector nut and lock nut have been removed the spacer stem can also be tightened over its hexagonal end Further information Further information e g required tightening torques can be found in the special docu mentation TV SK 9626 7 inquiries Please submit the following details Type designation and order number on nameplate Serial number nominal size and version of the valve Pressure and temperature of the process medium Flow rate in m3 h Bench range spring range e g 0 2 to 1 bar of the actuator Installation drawing Dimensions Refer to the Data Sheet T 8093 EN for the dimensions and weights of the various valve versions 14 EB 8093 8093 EN 15 SAMSON AG MESS UND REGELTECHNIK Weism llerstraBe 60314 Frankfurt am Main Germany Phone 49 69 4009 0 Fa
13. read on the stem connector nut 9 by hand until it touches the actuator stem A 7 and then turn it a further turn Secure this position with the lock nut 10 8 Position clamps of the stem connector A 51 and fasten tight Assembling and adjusting valve and actuator 9 Align travel indicator scale 84 with tip of the stem connector for actuators with Actuator stem extends align it with lower marking valve closed and for ac tuators with Actuator stem retracts align it with top marking valve open 2 1 Option to pretension the springs for actuator version Actuator stem extends To achieve a greater thrust the actuator springs can be pretensioned by 12 5 240 cm by 25 350 and 700 cm or by 75 700 cm of their travel or their bench range If with a bench range of 0 2 to 1 bar the springs are to be pretensioned by 0 1 bar for example the bench range is shifted by 0 1 bar to 0 3 bar When adjusting the valve a signal pressure of 0 3 bar is to be set as the lower signal pressure range The new bench range of 0 3 to 1 1 bar must be marked on the nameplate as the bench range with pretensioned springs EB 8093 7 Installation 2 2 Valve and actuator that have different rated travels Actuators with springs that have already been pretensioned by the manufacturer without attachment to a valve are marked by an appropriate label In addition such actuators can be identified by three
14. s and threaded bushing 8 Slide spring 11 washer 12 and new packing rings 16 over the spacer stem into the packing chamber Put on threaded bushing 8 and tighten it as far as it will go Table 1 Tightening torques in Nm for steel and aluminum versions Body nuts 33 14 Nominal size Seat 4 material Bellows Spacer Globe valve 33 Aluminum pus on ws zn 24360 Qao 15 25 Vo su 160 170 130 200 40 50 30 30 B27 son esee 480 500 380 1000 80 80 40 30 653 802723 900 1050 800 2000 150 110 60 30 100 4 1250 1550 1150 3200 130 150 100 40 150 6 2300 2600 2000 3840 130 190 120 40 8093 11 Protective cover 6 Screw the lock nut 10 and nut 9 loosely onto the spacer stem 71 7 Mount actuator and adjust the lower or upper bench range as described in sec tion 2 6 Protective cover To keep the overall height of the valve as small as possible for transportation purposes in cold box installations the actuator and valve bonnet must be removed from the flanged section of the cryogenic extension bonnet and the bellows stem protected by a protective cover General The protective cover with adjustment bolt must meet the following requirements when the valve is installed in the plant Opening the valve to its rated travel to allow the pipeline and the valve to be rinsed Closing the valve to perform a pressure tes
15. t to check the tightness of the plant section The bellows seal in this case is the primary sealing element The protec tive cover merely serves to transfer the force Description of the function In the delivered state the protective cover is mounted and the valve is open the thread of the bellows stem is completely screwed into the adjustment bolt To perform the leak test in the plant section the adjustment bolt must be threaded coun terclockwise valve closed 32 33 95 7 95 5 95 6 Fig 7 Protective cover E linksdrehen zum Schlie en counter clockwise to close 2 ARASAN 95 3 95 4 95 9 95 1 95 2 Schlie kraft closing force Legend 32 Stud 33 Nut 37 Bellows stem with 42 43 95 1 95 2 95 3 95 4 95 5 25 6 25 79 7 metal bellows Test connection Flat gasket Protective cover Adiustment bolt SW 19 Retaining ring O ring Screw plug Flat gasket O ring Spacer sleeve washer 12 Eb 8093 EN If the adjustment bolt is turned clockwise the plug is lifted out of the seat valve opens Mounting the protective cover Note For actuators with fail safe action Actuator stem extends and especially actuators with pretensioned springs apply a pressure beforehand to retract the actuator stem slightly 1 Remove the mounted actuator as de scribed in sect
16. x 49 69 4009 1507 Internet http www samson de EB 8093 EN S Z 2011 01
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