Mounting and Operating Instructions EB 8051 EN
Contents
1. sesseesoeesoessoesoossossseesocesoessossseesosee 5 Notes on possible severe personal injury 1 7 Notes on possible personal injury 1 8 Notes on possible property damage seen 9 Markings on the control valve eeeee eee eese eene eene eene 10 Valve namepldie een ee es 10 olo EE 11 Material number cenis eM 11 Design and principle of operation cese eere eere eere eene nen 12 Failsafe OSI OMS re 12 eege 14 Technica 14 Wl 20 E T 20 Transporting and lifting 20 NO ee ee ee nie 21 Mile Uu 21 SLO ee EA AE A 24 Ereegnes 25 O EIWOOEENEB Ch GT ceres serene eere enero eee 26 Mounting the actuator onto the valve 26 Installing the valve into the pipeline nennennenenn 27 Checking the installation conditions 27 IRNOS E 28 Installing the control 29 BIS EE 29 Operaho Meerssen 31 Working in manual MOE Pf UTERIS ei ue 32 Replacing Ihe packing EE 33 Standard valve GEIER anne 33 Valves with insulating section or bellows sel 34 EB 8051 EN 3 Contents rey g 7 2 2 1 3 73 7 3 2 7 4 7 9 7 6 8 1 8 2 9 1 9 2 Ta 9 4 10 10 1 10 2 10 32. attached slings The lifting eyelet on the actuator is only intended for mounting and re moving the actuator as well as lifting the actuator without valve Do not use this lifting eyelet to lift the entire control valve assembly When lifting the control valve make sure that the slings attached to the valve body bear the entire load Do not attach load bearing slings the actuator handwheel or any other parts Observe lifting instructions see section 4 2 2 Tip SAMSON s After sales Service de partment can provide more detailed transport and lifting instructions on request EB 8051 EN Preparation 4 2 1 The control valve can be transported using lifting equipment e g crane or forklift Transporting gt Leave the control valve in its transport container or on the pallet to transport it gt Observe the transport instructions Transport instructions Protect the control valve against external influences e g impact Do not damage the corrosion protection paint surface coatings Remove any damage immediately Protect the control valve against moisture and dirt The permissible transportation tempera ture of standard control valves is 20 to 65 Note Contact SAMSON s After sales Ser vice department for the transporta tion temperatures of other valve ver sions 4 2 2 Lifting To install a large valve into the pipeline use li
3. gt Check whether the valve moves to the fail safe position 30 EB 8051 EN Operation 6 Operation Immediately after completing mounting and start up see section 5 the valve is ready for Use WARNING Crush hazard arising from moving parts actuator and plug stem Do not insert hands or finger into the yoke while the valve is in operation i NOTICE Operating disturbed by a blocked actuator and plug stem Do not impede the movement of the actuator or plug stem by inserting objects into their path 6 1 Working in manual mode Valves fitted with actuators with a handwheel can be manually closed or opened in case of supply air failure 2 For normal closed loop operation move the handwheel to the neutral position EB 8051 EN 31 Maintenance 7 Maintenance The control valve is subject to normal wear especially at the seat plug and packing De pending on the operating conditions check the valve at regular intervals to prevent pos sible failure before it can occur VV Tip SAMSON s After sales Service de partment can support you to draw up a maintenance plan for your plant External leakage can indicate that the pack ing is defective or the metal bellows is defec tive in a version with a bellows seal If the valve does not close tightly tight shut off may be impaired by dirt stuck between the seat and plug or by damaged facings We recommend removing the valve from the pipeline or ser
4. Install the valve into the pipeline see sec tion 5 2 After installation in the pipeline check whether the flanges are bolted tight and the valve in the pipeline holds Remove slings Tip Preparation Version with welding ends l Attach one sling to each welding end of the body and to the rigging equipment e g hook of the crane or forklift see Fig 4 Secure the slings attached to the body against slipping using a connector DN 150 and larger Attach another sling to the lifting eyelet on the actuator and to the rigging equipment Carefully lift the control valve Check whether the lifting equipment and acces sories can bear the weight Move the control valve at an even pace to the site of installation Install the valve into the pipeline see sec tion 5 2 After installation in the pipeline check whether the weld seams hold Remove slings We recommend using a hook with safety latch see Fig 4 The safety latch prevents the slings from slipping during lifting and transporting EB 8051 EN 23 4 3 D Preparation Storage NOTICE Risk of valve damage due to im proper storage Observe storage instructions Avoid long storage times Contact SAMSON in case of differ ent storage conditions or longer storage times Note We recommend regularly checking the control valve and the prevailing storage conditions during long stor age times Storage ins
5. them The inlet and outlet lengths vary depending on the process medium To ensure the control valve functions properly follow the installa tion instructions given below Table 5 Inlet and outlet lengths Flow rate Inlet length Outlet length Valve conditions medium Ma x 0 3 Gas 0 3 lt lt 0 7 lt 0 31 0 3 lt lt 0 71 Saturated steam percentage of condensate gt 5 Free of cavitation w lt 10 m s Cavitation producing noise w x 3 m s Liquid Cavitation producing noise 3 w 5 m s Critical cavitation w lt 3 m s Critical cavitation 3 w 5 m s Flashing Multi phase 1 No saturated steam Vapor EB 8051 EN 27 Mounting and start up Mounting position We recommend installing the valve upright with the actuator on top Valves which are not installed in the pipe line in the upright position with the actuator on top must be supported or suspended The deadweight of the control valve may lead to premature wear or leakage if it is not supported or suspended In the following versions the valve must be installed in the upright position with the actu ator on top Valves in DN 100 and larger Valves with insulating section for low temperatures below 10 C gt Contact SAMSON if the mounting posi tion is not as specified here Vent plugs Vent plugs are screwed into the exhaust air ports of pneumatic electropneumatic and electric devices Th
6. Please submit the following details Order number and position number in the order Type model number nominal size and valve version Pressure and temperature of the process medium Flow rate in m3 h Bench range of the actuator e g 0 2 to 1 bar Isa strainer installed Installation drawing 42 EB 8051 EN Appendix 10 2 Certificates ce modul h de en rev00 docx Konformitatserklarung Declaration of Conformity Modul Module H N CE PED H SAM 001 13 DEU Fur folgende Produkte For the following pressure equipment Ger te Devices Bauart Series Typ Type Ausf hrung Version DIN Gehause GG Cast iron Body ab from DN150 Geh use GGG Sph Durchgangsventil Globe Valve 240 3241 gr iron Body ab from DN100 Fluide Fluids DIN ANSI Geh Stahl u a Body Steel etc alle Fluide all Fluids DIN Gehause GG ab DN150 Cast iron Body from DN150 Geh use GGG Dreiwegeventil Three way Valve 240 3244 ab DN100 Sph gr iron Body from DN100 Fluide Fluids DIN ANSI Geh Stahl u a Body Steel etc alle Fluide all Fluids Tieftemperaturventil Cryogenic Valve 240 3248 DIN ANSI alle Fluide all Fluids Durchgangsventil Globe Valve 250 3251 DIN ANSI alle Fluide all Fluids Dreiwegeventil Three way Valve 250 3253 DIN ANSI Geh Stahl u a Body Steel etc alle Fluide all Fluids Durchgangsventil Globe Valve 250 3254 DIN ANSI alle Fluide all Fluids Eckventil Angle Valve 25
7. Signal pressure Lock nut Diaphragm connection O Fig 3 Type 3251 Valve with Type 3271 Pneumatic Actuator left and Type 3277 Pneumatic Actuator right EB 8051 EN 13 Design and principle of operation 3 2 Versions The modular design allows an insulating sec tion or metal bellows to be fitted to the stan dard valve version Actuators In these instructions the preferable combina tion with a Type 3271 or Type 3277 Pneu matic Actuator is described The pneumatic actuator with or without handwheel can be replaced by another pneumatic actuator in a different size but with the same travel gt Observe the maximum permissible actu ator force Note If the travel range of the actuator is larger than the travel range of the valve the spring assembly in the ac tuator must be preloaded so that the travel ranges match See associated actuator documentation The basic pneumatic actuator can be re placed by a pneumatic actuator with addi tional handwheel or by an electric actuator 3 3 Technical data The nameplates on the valve and actuator provide information on the control valve ver sion See section 2 1 and the associated ac tuator documentation Note More information is available in Da ta Sheet gt T 8051 Compliance The Type 3251 Valve bears both the CE and EAC marks of conformity Ce Temperature range Depending on the version the control valve is designed for a temperature ran
8. injuries due to hot or cold components and pipelines Depending on the process medium valve components and pipelines may get very hot or cold and cause burn injuries gt Allow components and pipelines to cool down or heat up gt Wear protective clothing and gloves Risk of personal injury due to preloaded springs Valves in combination with pneumatic actuators with preloaded springs are un der tension These control valves with SAMSON pneumatic actuators can be identified by the long bolts protruding from the bottom of the actuator gt Before starting any work on the actuator relieve the compression from the preloaded springs see associated actuator documentation 8 EB 8051 EN Safety instructions and safety measures 1 3 Notes on possible property damage NOTICE Risk of valve damage due to contamination e g solid particles in the pipe line gt Flush the pipelines before start up Risk of valve damage due to unsuitable medium properties The valve is designed for a process medium with defined properties Only use the process medium specified for sizing the valve Risk of leakage and valve damage due to excessively high or low tightening torques Observe the specified torques on tightening control valve components Excessive ly tightened torques lead to parts wearing out quicker Parts that are too loose may cause leakage gt Observe the specified tightening torques WA 0029 Risk of valv
9. of the operator The operator is responsible for proper operation and compliance with the safety regulations Operators are obliged to provide these mounting and operating instructions to the operating personnel and to instruct them in proper operation Furthermore operators must ensure that operating personnel or third persons are not exposed to any danger Responsibilities of operating personnel Operating personnel must read and understand these mounting and operating instructions as well as the specified hazard statements warning and caution notes Furthermore the operat ing personnel must be familiar with the applicable health safety and accident prevention regulations and comply with them 6 8051 Safety instructions and safety measures Referenced standards and regulations The control valves comply with the requirements of the European Pressure Equipment Direc tive 97 23 EC Valves with a CE marking have a declaration of conformity which includes information about the applied conformity assessment procedure This declaration of confor mity is included in the Appendix of these instructions see section 10 2 According to the ignition risk assessment performed in accordance with EN 13463 1 2009 section 5 2 the non electrical control valves do not have their own potential ignition source even in the rare incident of an operating fault As a result they do not fall within the scope of Directive 94 9 EC gt For co
10. of valve damage due to the use of unsuitable tools Only use tools approved by SAMSON gt WA 0029 NOTICE Risk of valve damage due to incor rect maintenance or repair Service and repair work must only be performed by trained staff Contact SAMSON s After sales Service department for service and repair work 7 1 Replacing the packing 7 1 1 Standard valve versions 1 Remove actuator See associated actua tor documentation 2 Remove body nuts 14 3 Lift the valve bonnet 2 and plug with plug stem 5 off the body 1 4 Unthread the stem connector nut 9 and lock nut 10 from the plug stem 5 Unscrew the threaded bushing 8 6 Pull the plug with plug stem 5 out of the valve bonnet 2 7 Pull all the packing parts out of the pack ing chamber using a suitable tool 8 Renew damaged parts Clean the pack ing chamber thoroughly EB 8051 EN Maintenance 9 Remove the gasket 17 and carefully clean sealing faces in the valve body 1 and on the bonnet 2 10 Apply a suitable lubricant to all the pack ing parts and to the plug stem 5 NOTICE Do not use lubricant on graphite packings 11 Slide the plug with plug stem 5 into the valve body 1 12 Insert the new gasket 17 into the body 13 Carefully place the valve bonnet 2 over the plug stem onto the valve body 1 Fasten with nuts 14 14 Carefully slide the packing parts over the plug stem into t
11. seat and plug Valve trim particularly with soft seat is worn Actuator is blocked Check attachment Unblock the actuator Check the signal pressure Check the signal pressure line for leakage Check the signal pressure Check the signal pressure line for leakage Replace packing see sec tion 7 1 or contact SAMSON s After sales Service department Replace metal bellows see sec tion 7 4 or contact SAMSON s After sales Service department Check the flange joint Replace the gasket at the flange joint Shut off the section of the pipe line and flush the valve Replace seat and or plug see section 7 2 or section 7 3 or contact SAMSON s After sales Service department Contact SAMSON s After sales Service department for malfunctions not listed in the EB 8051 EN 8 2 Emergency action Upon supply air or control signal failure the valve moves to its fail safe position see sec tion 3 1 Operators are responsible for emergency ac tion to be taken in the plant In the event of a valve malfunction 1 Close the shut off valves upstream and downstream of the control valve to stop the process medium from flowing through the valve 2 Check the valve for damage If neces sary contact SAMSON s After sales Ser vice department Putting the valve back into operation after a malfunction Slowly open the shut off valves Allow the process medium to flow into the valve slowly EB 80
12. transportation damage Report any damage to SAM SON and the forwarding agent refer to delivery 4 1 Unpacking Note Do not remove the packaging until immediately before installing the valve into the pipeline Proceed as follows to lift and install the valve 1 Remove the packaging from the valve 2 Dispose of the packaging in accordance with the valid regulations Risk of valve damage due to foreign particles entering the valve The protective caps fitted on the valve s inlet and outlet prevent for eign particles from entering the valve and damaging it Do not remove the protective caps until immediately before installing the valve into the pipeline 20 4 2 A Transporting and lifting DANGER Hazard due to suspended loads fall ing Stay clear of suspended or moving loads WARNING Risk of lifting equipment tipping and risk of damage to lifting accessories due to exceeding the rated lifting ca pacity Only use approved lifting equip ment and accessories whose mini mum lifting capacity is higher than the weight of the valve including actuator if applicable Refer to section 3 3 or Data Sheet gt T 8051 for weights WARNING Risk of personal injury due to control valve tipping Observe the valve s center of gravity Secure the valve against tipping over or turning EB 8051 EN NOTICE Risk of valve damage due to incor
13. valve components Excessively tightened torques lead to parts wearing out quicker Parts that are too loose may cause leakage Observe the specified tightening torques WA 0029 NOTICE Risk of valve damage due to the use of unsuitable tools Only use tools approved by SAMSON gt WA 0029 5 1 Mounting the actuator onto the valve Proceed as described in the actuator docu mentation if the valve and actuator have not been assembled by SAMSON Note Remove the mounted actuator be fore mounting the other actuator see associated actuator documen tation Preloading the actuator springs in creases the thrust of a pneumatic actuator and reduces the travel range of the actuator see associat ed actuator documentation DN 100 and larger in versions with V port plug the large V shaped port of the V port plug must face towards the valve outlet on mounting the actuator EB 8051 EN Mounting and start up 5 2 Installing the valve into the gt Observe the inlet and outlet lengths see jq Table 5 Contact SAMSON if the valve pipeline conditions or states of the medium pro 5 2 1 Checking the installation Zeie conditions Install the valve free of stress and with the least amount of vibrations as possible If Pipeline routing necessary attach supports to the valve 2 Install the valve allowing sufficient space to remove the actuator and valve or to perform service and repair work on
14. 0 3256 DIN ANSI alle Fluide all Fluids Split Body Ventil Split Body Valve 250 3258 DIN alle Fluide all Fluids IG Eckventil IG Angle Valve 250 3259 DIN alle Fluide all Fluids 3281 DIN ANSI alle Fluide all Fluids Dampfumformventil 280 3284 DIN ANSI alle Fluide all Fluids Steam converting Valve 3286 DIN ANSI alle Fluide all Fluids 3288 DIN alle Fluide all Fluids DIN Geh Stahl u a Body Steel etc alle Fluide all Fluids Durchgangsventile Globe Valve V2001 3321 ANSI alle Fluide all Fluids Dreiwegeventil Three way Valve V2001 3323 DIN Geh Stahl u a Body Steel etc alle Fluide all Fluids ANSI alle Fluide all Fluids Schragsitzventil Bevel Valve 3353 DIN Geh Stahl Body Steel alle Fluide all Fluids 3381 1 DIN ANSI alle Fluide all Fluids Einzeldrosselscheibe mit Anschwei ende Single attenuation plate with welding end Drosselschalldampfer Silencer 3381 3381 3 DIN ANSI alle Fluide all Fluids 3381 4 DIN ANSI alle Fluide all Fluids Einzeldrosselscheibe mehrstufig mit Anschwei ende Single attenuation plate multi stage with welding end ANSI Geh use GG C1125 ab 5 Cast iron Body Cl125 from 5 Fluide Fluids Durchgangsventil Globe Valve 240 3241 Tieftemperaturventil mit Zirkulationssperre Cryogenic Valve with Circulation Barrier 240 3246 DIN ANSI alle Fluide all Fluids DIN Gehause GG ab DN200 PN16 Cast iron Body from DN200 PN16 Dreiwegeventil Three way Valve 250 3253 Fluide
15. 51 EN Decommissioning and disassembly 9 Decommissioning and disas sembly DANGER Risk of bursting in pressure equip ment Control valves and pipelines are pressure equipment Improper open ing can lead to bursting of the valve Before starting any work on the control valve depressurize all plant sections concerned and the valve Drain the process medium from all the plant sections concerned as well as the valve Wear personal protective equip ment WARNING Risk of personal injury due to resid ual process medium in the valve While working on the valve residual process medium can escape and de pending on its properties may lead to personal injury e g chemical burns Wear protective clothing gloves and eyewear WARNING Risk of burn injuries due to hot or cold components and pipeline Valve components and the pipeline may become very hot or cold Risk of burn injuries 39 Decommissioning and disassembly Allow components and pipelines to cool down or heat up Wear protective clothing and gloves 9 1 To decommission the control valve for service and repair work or disassembly proceed as follows Decommissioning 1 Close the shut off valves upstream and downstream of the control valve to stop the process medium from flowing through the valve 2 Completely drain the pipelines and valve 3 Disconnect and lock the pneumatic air supply to depressurize the a
16. Fluids 1 Durchgangsventil Globe Valve 290 3291 ANSI alle Fluide all Fluids Eckventil Angle Valve 290 3296 ANSI alle Fluide all Fluids Durchgangsventil Globe Valve 590 3591 ANSI alle Fluide all Fluids Eckventil Angle Valve 590 3596 ANSI alle Fluide all Fluids E Gase nach Artikel 3 Punkt 1 3a zweiter Gedankenstrich Gases acc to article 3 chapter 1 3a second line Fl ssigkeiten nach Artikel 3 Punkt 1 3b Liquids acc to article 3 chapter 1 3b wird die Konformitat mit nachfolgender Anforderung best tigt We declare conformity with the demands of the Richtlinie des Rates zur Angleichung der Rechtsvorschriften der 97 23 EG vomlof 29 05 1997 Mitgliedsstaaten ber Druckgerate Pressure Equipment Directive 97 23 EC mis Angewandtes Konformitatsbewertungsverfahren Applied Conformity Assessment Procedure durch by Modul H Module H Bureau Veritas 0062 f r Fluide nach Artikel 3 Absatz 1 for fluids acc to art 3 para 1 Das Qualit tssicherungssystem des Herstellers wird von folgender benannten Stelle berwacht The Manufacturer s Quality Assurance System is monitored by following Notified Body Bureau Veritas S A nr 0062 67 71 boulevard du Ch teau 92200 Neuilly sur Seine France Angewandte technische Spezifikation Technical Standards used DIN EN12516 2 DIN EN12516 3 ASME B16 34 Hersteller Manufacturer SAMSON AG Weism llerstra e 3 60314 Frankfurt Frankfurt 01 12 2014 e f Chak e Eugen N
17. Replacing Ihe sedl E 34 Standard valve versions 34 Valves with insulating section or bellows sel 34 Me ee ee A NI CPV UE 34 Standard eg 36 Valves with insulating section or bellows sel 36 Replacing the metal bellows valves with bellows seal only 36 Preparation for return ahipment 36 Ordering spare parts and operating supplies nennen 87 Malfunc hons 38 38 Emergency nee een 37 Decommissioning and disassembly ssccssscsssscsssscsssscsssscssccsssscssnseeees 39 SCENTS ONN ee en ee 40 Removing the valve from the pipeline sse 40 Removing the actuator from the valve 40 K 40 42 En 42 UE 43 SPOTE TD TT 44 8051 Safety instructions and safety measures 1 Safety instructions and safety measures Intended use The SAMSON Type 3251 Globe Valve in combination with an actuator e g Type 3271 or Type 3277 Pneumatic Actuator is designed to regulate the flow rate pressure or temperature of liquids gases or vapors The valve with its actuator is designed to operate under exactly defined conditions e g operating pressure process medium temperature Therefore opera tors must ensure that the control valve is only used in applications that meet the specifications used for si
18. Type 3251 Valve In combination with an actuator e g a SAMSON Type 3271 or Type 3277 Pneumatic Actuator DIN version Type 3251 Valve with Type 3271 Actuator Mounting and Operating Instructions EB 8051 EN Edition June 2015 Translation of original instructions Referenced documentation The following documents apply in addition to these mounting and operating instructions Mounting and operating instructions for mounted actuator e g EB 8310 for SAM SON Type 3271 and Type 3277 Actuators Mounting and operating instructions for mounted valve accessories positioner solenoid valve etc b WA 002 for tools and lubricant The mounting and operating instructions for all supplied devices are included in the delivery The latest versions of the documents are available on our website at gt www samson de gt Product documentation Definition of signal words DANGER Hazardous situations which if not Property damage message or mal avoided will result in death or seri function ous Injury Hazardous situations which if not avoided could result in death or seri ous Injury Tip Recommended action ge Note WARNING Additional information 2 EB 8051 EN 1 1 1 2 1 3 2 1 2 2 2 3 3 1 32 3 3 4 1 4 2 4 2 1 4 2 2 4 3 4 4 5 1 5 2 5 2 1 22 5 2 3 5 2 4 6 1 7 1 7 1 1 7 1 2 Contents Safety instructions and safety measures
19. alve damage due to a sud den pressure increase and resulting high flow velocities Slowly open the shut off valve in the pipeline during start up 8 Check the valve to ensure it functions properly and that there is no leakage Version with welding ends 1 Proceed as described for Version with flanges steps 1 to 3 2 Completely retract the actuator stem to protect the plug from sparks during weld ing 3 Weld the valve free of stress into the pipeline 4 Proceed as described for Version with flanges steps 6 to 8 5 2 4 Quick check SAMSON valves are delivered ready for use To test the valve s ability to function the following quick checks can be performed 29 Mounting and start up Packing For versions with adjustable packing Form H check whether the packing is correctly tightened to prevent process medium escap ing during start up vv Tip AK A label on the bonnet 2 or yoke 3 indicates whether an adjustable packing is installed 2 Slightly turn the packing nut clockwise with a suitable tool to tighten the pack ing Travel motion The movement of the actuator stem must be linear and smooth gt Open and close the valve observing the movement of the actuator stem gt Apply the maximum and minimum con trol signals to check the end positions of the valve gt Check the travel reading at the travel in dicator scale Fail safe position gt Shut off the signal pressure line
20. ctuator 4 If necessary allow the pipeline and valve components to cool down or heat up 9 2 Removing the valve from the pipeline Version with flanges 1 Put the control valve out of operation see section 9 1 2 Unbolt the flange joint 3 Remove the valve from the pipeline see section 4 2 Version with welding ends 1 Put the control valve out of operation see section 9 1 2 Cut the pipeline in front of the weld seam 40 3 Remove the valve from the pipeline see section 4 2 9 3 Removing the actuator from the valve See associated actuator documentation 9 4 Disposal gt Observe local national and internation al refuse regulations Do not dispose of components lubricants and hazard substances together with your other household waste EB 8051 EN Decommissioning and disassembly EB 8051 EN 41 Appendix 10 Appendix 10 1 Customer inquiries Contact SAMSON s After sales Service de partment for support concerning mainte nance or repair work or when malfunctions or defects arise E mail You can reach the After sales Service depart ment at aftersalesservice samson de Addresses of SAMSON AG and its subsid iaries The addresses of SAMSON its subsid iaries representatives and service facilities worldwide can be found on the SAMSON website in all SAMSON product catalogs or on the back of these Mounting and Operat ing Instructions Required specifications
21. e damage due to the use of unsuitable tools Certain tools are require to work on the valve gt Only use tools approved by SAMSON WA 0029 Risk of valve damage due to the use of unsuitable lubricants The lubricants to be used depend on the valve material Unsuitable lubricants may corrode and damage the valve surface Only use lubricants approved by SAMSON WA 0029 EB 8051 EN 9 Markings on the control valve 2 Markings on the control valve 2 1 SAMSON Valve nameplate 8 74 9 1 CE marking or Art 3 Abs 3 where applicable ID of the notified body fluid group and category where applicable Type designation Device modification index Material Year of manufacture Valve size DIN DN ANSI NPS JIS DN Pressure rating DIN ANSI JIS Order no with modification index Position in order Flow coefficient DIN Kys ANSI Cy JIS Cy Characteristic equal percentage Lin linear NO NC on off service Seat plug seal ME metal see section 3 3 HA carbide metal ST Stellite facing KE ceramic PT soft seal with PTFE PK soft seal with PEEK Pressure balancing DIN D ANSI B JIS B Flow divider 1 StI 3 St Ill Fig 1 Valve nameplate EB 8051 EN Markings on the control valve The nameplate 80 is affixed to the yoke of the valve see Fig 2 Stellite 6B CrNiMo steel with en tire seat bore with Stellite fac
22. ebel Stephan Michalik Zentralabteilungsleiter Head of Central Department Zentralabteilungsleiter Head of Central Department Entwicklung Stellger te Control Valve Development Qualit tsmanagment Quality Management 2 SAMSON AKTIENGESELLSCHAFT Weism llerstraBe 3 60314 Frankfurt am Main GROUP Telefon 49 69 4009 0 Telefax 4969 4009 1507 Internet http www samson de Revision 00 8051 43 Appendix 10 3 Spare parts Legend 1 2 Bonnet flange 3 Yoke 4 Seat 5 Plug 6 Bellows nut 7 Guide bushing 8 Threaded bushing 9 Stem connector nut 10 Lock nut 11 Spring 12 Washer 13 Stud bolt 14 Nut 15 Packing adjustable 16 Packing 17 Gasket 19 Bushing 21 Insulating section 22 Bellows seal 24 Guide bushing 26 Label bellows seal or insulating section adios Fastenin t 31 34 gt 29 Plug for version with bellows sea 30 Washers 32 Bolt 33 Nut 37 Plug stem with bellows 39 Gasket 42 43 Screw plug with seal 44 44 45 46 47 48 49 50 51 52 53 61 62 63 64 65 80 81 82 83 84 85 91 73 94 101 Ring ring nut Packing ring Gasket Support Hexagon screw Hexagon screw Lock Guide several guides only for version with graphite seal Ring only for version with graphite seal Snap ring Flow divider II 2 Flow divider or III Ring Gasket Gasket Nameplate Grooved pin Screw Hanger Travel ind
23. ey ensure that any ex haust air that forms can be vented to the at mosphere to avoid excess pressure in the device Furthermore the vent plugs allow air intake to prevent a vacuum from forming in the device Locate the vent plug on the opposite side to the workplace of operating personnel gt On mounting valve accessories make sure that they can be operated from the workplace of the operating personnel 28 Note The workplace of operating person nel is the location from which the valve actuator and any mounted valve accessories can be accessed to operate them D 5 2 2 Additional fittings Strainer We recommend installing a SAMSON Type 2 Strainer upstream of the valve It pre vents solid particles in the process medium from damaging the valve Bypass and shut off valves We recommend installing a shut off valve both upstream of the strainer and down stream of the valve and setting up a bypass line The bypass line ensures that the plant does not need to be shut down for service and repair work on the valve Insulation Only insulate control valves with insulating section or bellows seal up to the bonnet flange of the valve body for medium tem peratures below 0 or above 220 Do not insulate valves mounted to comply with NACE MR 0175 requirements Test connection Versions with bellows seal fitted with a test connection Vs at the top flange allow the tightness of the bellows to be
24. fting equipment e g crane or forklift to lift it Lifting instructions Secure slings against slipping Make sure the slings can be removed from the valve once it has been installed into the pipeline 21 Preparation Prevent the control valve from tilting or control valve from tilting while being lift tipping ed Before lifting the control valve tight Do not leave loads suspended when in en the sling terrupting work for longer periods of time Make sure that the axis of the pipeline is always horizontal during lifting and the axis of the plug stem is always vertical Make sure that the additional sling be tween the lifting eyelet and rigging equipment hook shackle etc does not bear any load when lifting valves larger than DN 150 The sling only protects the Fig 4 Lifting points on the control valve up to DN 150 left and with welding ends middle DN 150 and larger with additional lifting eyelet on the actuator right 22 EB 8051 EN Version with flanges l 4 Attach one sling to each flange of the body and to the rigging equipment e g hook of the crane or forklift see Fig 4 DN 150 and larger Attach another sling to the lifting eyelet on the actuator and to the rigging equipment Carefully lift the control valve Check whether the lifting equipment and acces sories can bear the weight Move the control valve at an even pace to the site of installation
25. ge from 10 to 220 C The use of an insulating section or bellows seal extends the tempera ture range from 196 to 550 C Leakage class Depending on the version the following leakage class applies Seal 13 on ME ST ME ST PT PK nameplate Pressure balancing 14 on D B nameplate Leakage class according to IEC 60534 4 EB 8051 EN Noise emission SAMSON is unable to make general state ments about noise emission as it depends on the valve version plant facilities and process medium On request SAMSON can perform calculations according to IEC 60534 Part 8 3 or VDMA 24422 edition 89 WARNING Risk of hearing loss or deafness due to loud noise Wear hearing protection when work ing near the valve EB 8051 EN Design and principle of operation 15 Design and principle of operation Dimensions and weights Table 1 to Table 4 provide a summary of the dimensions and weights of the standard version of Type 3251 Valve The lengths and heights in the dimensional drawings are shown on p 18 Dimensions in mm Weights in kg Table 1 Dimensions of Type 3251 Valve up to DN 150 Face to face dimensions according to DIN EN 558 flanges had 260 300 350 A50 520 welding 260 300 350 450 520 ends 152 164 222 314 88 418 418 418 418 418 503 480 503 503 E 100 and larger with foot Face to face dimensions acc to SAMSON standard 16 EB 8051 EN Design and princi
26. he packing chamber Make sure you observe the proper order see Fig 5 D Note The number of spacers 18 19 var ies depending on the nominal valve size 15 Screw in the threaded bushing 8 and tighten it 16 Loosely screw the lock nut 10 and stem connector nut 9 onto the plug stem 17 Mount actuator See associated actuator documentation 18 Adjust lower or upper signal bench range See associated actuator docu mentation 33 Maintenance Jd N f ee SO ER age 7 NA DDDIZZZZ ZZZ D SSS e EEE 3 ee Se i LLB SLi ZS 8 Threaded bushing IX E IDZ X gt gt 11 Spring 12 Washer 16 V ring 18 19 Spacer N N N N lt lt lt aA FUN Fig 5 Packing in standard valve versions 7 1 2 Valves with insulating section or bellows seal To replace the packing proceed as de scribed for the standard version in sec tion 7 1 1 However gt Unscrew the threaded bushing 8 Remove the nuts 33 Separate the bel lows bonnet 101 from the bellows seal 22 2 Replace the gasket 39 34 7 2 Replacing the seat When exchanging the seat we recommend also checking the plug and packing and to replace them as well if necessary 7 2 1 Standard valve versions 1 To replace the seat proceed as described in section 7 1 1 items 1 to 7 2 Unscrew the seat 4 using a suitable seat wrench WA 0029 3 Apply a su
27. icator scale Screw Protective caps Nut Expansion sleeve Expansion sleeve Bellows bonnet 102 103 Screw with snap ring only for 1 2 version with bellows seal Version with balanced valve plug Version with flow divider EB 8051 EN 80 81 83 84 DN 15 150 NPS VG i 102 103 EB 8051 EN 46 EB 8051 EN EB 8051 EN 47 SAMSON AG MESS UND REGELTECHNIK Weism llerstraDe 60314 Frankfurt am Main Germany Phone 49 69 4009 0 Fax 49 69 4009 1507 samson samson de www samson de EB 8051 EN 2015 07 08 English
28. ing L 39 2 2 Actuator nameplate See associated actuator documentation Fig 2 Location of the nameplate 2 3 Material number The seat and plug of the valves have an arti cle number written on them Specilying this article number you can contact us to find out which material is used Additionally a seat code is used to identify the trim material This seat code is specified on the nameplate seat plug seal 13 For more details on the nameplate see section 2 1 EB 8051 EN 11 Design and principle of operation 3 Design and principle of oper ation The single seated Type 3251 Globe Valve is preferably combined with a SAMSON Type 3271 or Type 3277 Pneumatic Actuator see Fig 3 It can also be combined with other actuators The seat 4 and plug with plug stem 5 are assembled in the body 1 The plug stem is connected to the actuator stem A7 by the stem connector A26 and is sealed by a spring loaded V ring packing 15 The springs in the pneumatic actuator A are lo cated either above or below the diaphragm A4 depending on the selected fail safe ac tion see section 3 1 A change in the signal pressure acting on the diaphragm causes the plug to move The actuator size is deter mined by the diaphragm area The medium flows through the valve in the direction indicated by the arrow A rise in signal pressure causes the force acting on the diaphragm in the actuator to increase The springs are co
29. itable lubricant to the thread and the sealing cone of the new seat 4 Screw in the seat 7 2 2 Valves with insulating section or bellows seal 1 To replace the seat proceed as described in section 7 1 1 items 1 to 7 and sec tion 7 1 2 2 Unscrew the seat 4 using a suitable seat wrench WA 0029 3 Apply a suitable lubricant to the thread and the sealing cone of the new seat 4 Screw in the seat 7 3 Replacing the plug When exchanging the plug we recommend also checking the seat and packing and to replace them as well if necessary EB 8051 EN Zr 7772 SIZZZZZ N N BESSE I AZAD DLS I 7 H SENE Pi nnnnmnn nne ENSS A HX d GENE NIN ARRA AZ 42 E N S S N NO N ES VA N C2 oo N De Fig 6 Valves with bellows seal DN 50 to 150 EB 8051 EN Maintenance Bellows nut Threaded bushing Bellows seal Flange Clamping ring Plug for version with bellows seal Nut Screw Plug stem with bellows Gasket Test connection Bellows bonnet 35 Maintenance 7 3 1 Standard valve versions 2 To replace the plug proceed as de scribed in section 7 1 1 Replace the old plug with a new plug 7 3 2 Valves with insulating section or bellows seal The plug stem can only be replaced as a unit together with the metal bellows The plug can however be detached from the plug stem The plug of val
30. monitored EB 8051 EN Particularly for liquids and vapors we rec ommend installing a suitable leakage indica tor e g a contact pressure gauge an outlet to an open vessel or an inspection glass WARNING Risk of personal injury due to compo nents under pressure and process medium escaping under pressure Do not loosen the screw of the test connection while the valve is in oper ation Safety guard To reduce the crush hazard arising from moving parts actuator and plug stem a safety guard can be installed Noise emission Trims with flow dividers can be used to re duce noise emission see T 8081 5 2 3 Installing the control valve Version with flanges 1 Close the shut off valve in the pipeline while the valve is being installed 2 Remove the protective caps from the valve ports before installing the valve 3 Lift the valve using suitable lifting equip ment to the site of installation see sec tion 4 2 2 Observe the flow direction through the valve The arrow on the valve indicates the direction of flow 4 Make sure that the correct flange gaskets are used EB 8051 EN Mounting and start up 5 Bolt the pipe to the valve free of stress 6 Depending on the field of application allow the valve to cool down or heat up to reach ambient temperature before start up 7 Slowly open the shut off valve in the pipeline after the valve has been in stalled Risk of v
31. mpressed Depending on the selected direction of action the actuator stem retracts or extends As a result the plug position in the seat changes and determines the flow rate through the valve 3 1 The fail safe position depends the actua tor used Fail safe positions Depending on how the compression springs are arranged in the pneumatic actuator the valve has two different fail safe positions Actuator stem extends When the signal pressure is reduced or the air supply fails the springs move the actua tor stem downward and close the valve The valve opens when the signal pressure is in creased enough to overcome the force exert ed by the springs Actuator stem retracts When the signal pressure is reduced or the air supply fails the springs move the actua tor stem upwards and open the valve The valve closes when the signal pressure is in creased enough to overcome the force exert ed by the springs vv Tip The actuator s direction of action can be reversed if required Refer to the operating and mounting instructions of the pneumatic actuator e g gt EB 8310 for 3271 and 3277 EB 8051 EN Design and principle of operation ey Om Bonnet Packing Yoke Gasket Seat Travel indicator scale Plug with plug stem Castellated nut Threaded bushing Stem connector nut Actuator Actuator stem Ring nut Spring Vent plug Stem connector clamps 2 3 4 5 8 9
32. nnection to the equipotential bonding system observe the requirements specified in section 6 3 of EN 60079 14 2014 10 VDE 0165 Part 1 1 1 Notes on possible severe personal injury N DANGER Risk of bursting in pressure equipment Control valves and pipelines are pressure equipment Improper opening can lead to valve components bursting gt Before starting any work on the control valve depressurize all plant sections concerned and the valve gt Drain the process medium from all the plant sections concerned as well as the valve gt Wear personal protective equipment EB 8051 EN 7 Safety instructions and safety measures 1 2 Notes on possible personal injury WARNING Crush hazard arising from moving parts The control valve contains moving parts actuator and plug stems which can in jure hands or fingers if inserted into the valve gt Do not insert hands or finger into the yoke while the valve is in operation gt While working on the control valve disconnect and lock the pneumatic air supply as well as the control signal Risk of personal injury due to residual process medium in the valve While working on the valve residual process medium can escape and depend ing on its properties may lead to personal injury e g chemical burns gt If possible drain the process medium from all the plant sections concerned and the valve gt Wear protective clothing gloves and eyewear Risk of burn
33. ple of operation Table 2 Dimensions of Type 3251 Valve DN 200 and larger Length L flanges and welding ends H8 for On request actuator 650 2 x 2800 H2 DN PN 63 to 160 390 100 and larger with foot 1 PN 63 2 H8 650 mm with 250 mm seat EB 8051 EN 17 Design and principle of operation Dimensional drawings Type 3251 Type 3251 Up to DN 80 without foot DN 100 and larger with foot Table 3 Weights for standard version of Type 3251 up to DN 150 L S NUCNMCNE SN NE EL PNl m40 155 vs zs s 2 78 2 A mann m s s o ns m without actuator On request Valve E without actuator 18 EB 8051 EN Design and principle of operation Note D Refer to the following data sheets for more dimensions and weights gt T 8051 for valves with bellows seal insulating section or heating jacket The associated actuator documentation applies to actuators e g for SAMSON pneu matic actuators gt T 8310 1 for Type 3271 and Type 3277 Actuators up to 750 cm actuator area gt T 8310 2 for Type 3271 Actuator with 1000 cm actuator area and larger as well as 3273 Actuator gt T 8310 3 for Type 3271 Actuator with 1400 60 cm actuator area EB 8051 EN 19 Preparation 4 Preparation After receiving the shipment proceed as fol lows 1 Check the scope of delivery Compare the shipment received against the deliv ery note 2 Check the shipment for
34. s and safety measures Personal protective equipment We recommend wearing the following protective equipment depending on the process medi um Protective clothing gloves and eyewear in applications with hot cold and or corrosive media Wear hearing protection when working near the valve gt Check with the plant operator for details on further protective equipment Revisions and other modifications Revisions conversions or other modifications to the product are not authorized by SAMSON They are performed at the user s own risk and may lead to safety hazards for example Fur thermore the control valve may no longer meet the requirements for its intended use Safety devices Upon supply air or control signal failure the valve moves to its fail safe position see sec tion 3 1 The fail safe action of the actuator is the same as its direction of action and is spec ified on the nameplate of SAMSON actuators see actuator documentation Warning against residual hazards To avoid personal injury or property damage plant operators and operating personnel must prevent hazards that could be caused in the control valve by the process medium the operat ing pressure the signal pressure or by moving parts by taking appropriate precautions They must observe all hazard statements warning and caution notes in these mounting and oper ating instructions especially for installation start up and maintenance Responsibilities
35. them up We recommend a storage temperature of 15 C for soft parts Store soft parts away from lubricants chemicals solutions and fuels Tip SAMSON s After sales Service de partment can provide more detailed storage instructions on request EB 8051 EN Preparation 4 4 Preparation for installation Proceed as follows gt gt gt gt Flush the pipelines Check the valve to make sure it is clean Check the valve for damage Check to make sure that the type desig nation nominal size material pressure rating and temperature range of the valve match the plant conditions size and pressure rating of the pipeline me dium temperature etc For steam applications make sure that the pipelines are dry Moisture will dam age the inside of the valve Check the pressure gauge to make sure it functions When the valve and actuator are al ready assembled check the tightening torques of the bolted joints gt WA 0029 Components may loosen during transport EB 8051 EN 25 Mounting and start up 5 Mounting and start up SAMSON valves are delivered ready for use In special cases the valve and actuator are delivered separately and must be assem bled on site The procedure to mount and start up the valve are described in the follow Ing 26 NOTICE Risk of valve damage due to exces sively high or low tightening torques Observe the specified torques on tightening control
36. tructions Valves in DN 100 and smaller can be stored horizontally Store valves larger than DN 150 in the upright position with the actuator on top to avoid damage to the seals packing chamber and pressure balancing If valves in DN 50 or larger are stored in one place for longer than six months store them in the upright position with the actuator on top Protect the control valve against external influences e g impact Do not damage the corrosion protection paint surface coatings Remove any damage immediately Protect the control valve against moisture and dirt Store it at a relative humidity of 24 less than 75 In damp spaces prevent condensation If necessary use a drying agent or heating Make sure that the ambient air is free of acids or other corrosive media The permissible storage temperature of standard control valves is 20 to 65 C Note Contact SAMSON s After sales Ser vice department for the storage tem peratures of other valve versions Do not place any objects on the control valve Pack the control valve in airtight packag ing Special storage instructions for soft parts Soft parts e g actuator diaphragm To protect soft parts against UV light and ozone pack them in black plastic bags We recommend using polyethylene pack aging with a minimum thickness of 0 075 mm Do not use PVC To keep soft parts in shape and to pre vent cracking do not bend them or hang
37. ves in DN 15 to 40 is screwed onto the stem The plug of valves in DN 50 and larger is attached to the stem us ing a clamping ring 28 NOTICE To prevent damage in the valve with bellows seal make sure that no torque is transferred to the metal bel lows which is welded onto the plug stem We recommend using a clamp ing tool gt WA 0029 A valve with insulating section does not contain a bellows Proceed for valves in DN 15 to 40 1 To replace the plug proceed as de scribed in section 7 1 1 Replace the old plug with a new plug 2 Screw nut 6 onto the plug stem by hand as far as it will go 3 Place the plug on the hexagonal neck of the plug stem 4 Place an open end wrench on the flat tened area of the plug stem and screw 36 the nut 6 onto the plug with a tighten ing torque of 40 Nm 7 4 Replacing the metal bel lows valves with bellows seal only The metal bellows can only be replaced as a unit together with the plug stem 37 gt To replace the metal bellows proceed as described in section 7 3 2 7 5 Preparation for return ship ment Defective valves can be returned to SAM SON for repair Proceed as follows to return valves to SAM SON 1 Put the control valve out of operation see section 9 2 Decontaminate the valve Remove any residual process medium 3 Fill in the Declaration on Contamination which can be downloaded from our website at www samson de gt Ser
38. vice or repair work see sec tion 9 2 Remove the affected parts as de scribed carefully clean them and renew them if necessary DANGER Risk of bursting in pressure equip ment Control valves and pipelines are pressure equipment Improper open ing can lead to bursting of the valve Before starting any work on the control valve depressurize all plant sections concerned and the valve Drain the process medium from all the plant sections concerned as well as the valve 32 Wear personal protective equip ment WARNING Risk of personal injury due to resid ual process medium in the valve While working on the valve residual process medium can escape and de pending on its properties may lead to personal injury e g chemical burns Wear protective clothing gloves and eyewear WARNING Risk of burn injuries due to hot or cold components and pipeline Valve components and the pipeline may become very hot or cold Risk of burn injuries Allow components and pipelines to cool down or heat up Wear protective clothing and gloves NOTICE Risk of valve damage due to exces sively high or low tightening torques Observe the specified torques on tightening control valve components Excessively tightened torques lead to parts wearing out quicker Parts that are too loose may cause leakage Observe the specified tightening torques WA 0029 EB 8051 EN Risk
39. vices gt Check lists for after sales service gt Declaration on Contamination 4 Send the valve together with the filled in form to your nearest SAMSON subsidi ary SAMSON subsidiaries are listed on our website at www samson de gt Worldwide EB 8051 EN Maintenance 7 6 Ordering spare parts and operating supplies Contact your nearest SAMSON subsidiary or the SAMSON After sales Service depart ment for information on spare parts lubri cants and tools Spare parts See section 10 3 for details on spare parts Lubricant Details on suitable lubricants can be found in the document WA 0029 Tools Details on suitable tools can be found in the document WA 0029 EB 8051 EN 37 Malfunctions 8 Malfunctions Depending on the operating conditions check the valve at certain intervals to prevent possi ble failure before it can occur Operators are responsible for drawing up a test plan 8 1 Troubleshooting Actuator or plug stem does not move on demand Actuator or plug stem does not move through the whole range The valve leaks to the atmo sphere fugitive emissions Increased flow through closed valve seat leakage Note table 38 Signal pressure too low Signal pressure too low The packing is defective Version with bellows seal the metal bellows seal is defective Flange joint loose or gasket worn out Dirt or other foreign particles de posited between the
40. zing the valve at the ordering stage In case operators intend to use the control valve in other applications or conditions than specified SAMSON must be contacted SAMSON does not assume any liability for damage resulting from the failure to use the valve for its intended purpose or for damage caused by external forces or any other external factors gt Refer to the technical data and nameplate for limits and fields of application as well as possible uses Reasonably foreseeable misuse The control valve is not suitable for the following applications Use outside the limits defined during sizing and in the technical data Use outside the limits defined by the valve accessories mounted on the control valve Furthermore the following activities do not comply with the intended use Use of non original spare parts Performing service and repair work not described in these instructions Qualifications of operating personnel The control valve must be mounted started up serviced and repaired by fully trained and qualified personnel only the accepted industry codes and practices are to be observed Ac cording to these mounting and operating instructions trained personnel refers to individuals who are able to judge the work they are assigned to and recognize possible hazards due to their specialized training their knowledge and experience as well as their knowledge of the applicable standards EB 8051 EN 5 Safety instruction
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