Samson 3248 Mounting And Operating Instructions

Mounting and
Operating Instructions

EB 8093 EN

Translation of original instructions

Edition November 2016

Type 3248 Valve

In combination with an actuator,

e.g. a SAMSON Type3271 or Type3277 Pneumatic Actuator

DIN version

2 EB 8093 EN

Note on these mounting and operating instructions

These mounting and operating instructions assist you in mounting and operating the device
safely. The instructions are binding for handling SAMSON devices.

Î For the safe and proper use of these instructions, read them carefully and keep them for

later reference.

Î If you have any questions about these instructions, contact SAMSON‘s After-sales Service

Department ([e-mail]).

The mounting and operating instructions for the devices are included in
the scope of delivery. The latest documentation is available on our website

(www.samson.de) > Product documentation. You can enter the document
number or type number in the [Find:] eld to look for a document.

Denition of signal words

Hazardous situations which, if not avoided,
will result in death or serious injury

Hazardous situations which, if not avoided,
could result in death or serious injury

Property damage message or malfunction

Additional information

Recommended action

DANGER

!

WARNING

!

NOTICE

!

Note

Tip

Contents

EB 8093 EN 3

1 Safety instructions and measures ...................................................................5

1.1 Notes on possible severe personal injury .........................................................8

1.2 Notes on possible personal injury ...................................................................9

1.3 Notes on possible property damage ..............................................................10

2 Markings on the control valve ......................................................................12

2.1 Valve nameplate ..........................................................................................12

2.2 Actuator nameplate ......................................................................................13

2.3 Material number ..........................................................................................13

3 Design and principle of operation ................................................................14

3.1 Fail-safe positions ........................................................................................17

3.2 Versions ......................................................................................................17

3.3 Technical data .............................................................................................18

4 Measures for preparation ............................................................................24

4.1 Unpacking ..................................................................................................24

4.2 Transporting and lifting ................................................................................24

4.2.1 Transporting ................................................................................................25

4.2.2 Lifting ..........................................................................................................26

4.3 Storage .......................................................................................................30

4.4 Preparation for installation ............................................................................31

5 Mounting and start-up ................................................................................. 32

5.1 Installing the valve into the pipeline ...............................................................32

5.1.1 Checking the installation conditions ...............................................................32

5.1.2 Additional ttings .........................................................................................34

5.1.3 Installing the control valve .............................................................................34

5.2 Removing the protective cover .......................................................................35

5.3 Mounting the actuator onto the valve .............................................................37

5.4 Quick check ................................................................................................38

6 Operation ...................................................................................................40

6.1 Working in manual mode ............................................................................. 40

4 EB 8093 EN

Contents

7 Servicing.....................................................................................................42

7.1 Replacing the gasket ....................................................................................43

7.1.1 Globe or angle valve, PN16 to 40 ...............................................................43

7.1.2 Globe or angle valve, PN63 and 100...........................................................44

7.2 Replacing the packing ..................................................................................45

7.2.1 Globe or angle valve, PN16 to 40 ...............................................................45

7.2.2 Globe or angle valve, PN63 and 100...........................................................46

7.3 Replacing the seat and plug ..........................................................................47

7.4 Replacing the bellows seal ............................................................................47

7.5 Preparation for return shipment ..................................................................... 47

7.6 Ordering spare parts and operating supplies .................................................47

8 Malfunctions ...............................................................................................48

8.1 Troubleshooting ...........................................................................................48

8.2 Emergency action ........................................................................................49

9 Decommissioning and disassembly ..............................................................50

9.1 Decommissioning .........................................................................................50

9.2 Removing the valve from the pipeline .............................................................50

9.3 Removing the actuator from the valve ............................................................50

9.4 Disposal ......................................................................................................50

10 Appendix ....................................................................................................52

10.1 After-sales service ........................................................................................52

10.2 Certicates ..................................................................................................52

10.3 Spare parts .................................................................................................55

EB 8093 EN 5

Safety instructions and measures

1 Safety instructions and measures

Intended use

The SAMSON Type3248 Globe and Angle Valve in combination with an actuator (e.g.
Type3271 or Type3277 Pneumatic Actuator) is designed to regulate the ow rate, pressure

or temperature of liquids or gases in cryogenic applications. For this purpose, the valves can
be welded into vacuum-insulated pipelines or cold boxes. The valve with its actuator is de­signed to operate under exactly dened conditions (e.g. operating pressure, process medi­um, temperature). Therefore, operators must ensure that the control valve is only used in ap-

plications that meet the specications used for sizing the valve at the ordering stage. In case
operators intend to use the control valve in other applications or conditions than specied,

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.

Î Refer to the technical data and nameplate for limits and elds of application as well as

possible uses.

Reasonably foreseeable misuse

The control valve is not suitable for the following applications:

− Use outside the limits dened during sizing and in the technical data

− Use outside the limits dened 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

Qualications of operating personnel

The control valve must be mounted, started up, serviced, and repaired by fully trained and

qualied personnel only; the accepted industry codes and practices are to be observed.

According 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.

6 EB 8093 EN

Safety instructions and measures

Personal protective equipment

We recommend wearing the following protective equipment depending on the process medi­um:

− Protective clothing, gloves, and eyewear in applications with cold or cryogenic and/or
corrosive media

− Wear hearing protection when working near the valve.

Î Check with the plant operator for details on further protective equipment.

Revisions and other modications

Revisions, conversions or other modications 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 product may no longer meet the requirements for its intended use.

Safety feature

Upon supply air or control signal failure, the valve moves to its fail-safe position (see sec­tion3.1). The fail-safe action of the actuator is the same as its direction of action and is spec­ied 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 oper­ating instructions, especially for installation, start-up, and service work.

Responsibilities 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 as well as the
referenced documents to the operating personnel and to instruct them in proper operation.
Furthermore, the operator 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 referenced documents and observe the hazard statements, warning and caution
notes specied in them. Furthermore, the operating personnel must be familiar with the ap-

plicable health, safety and accident prevention regulations and comply with them.

EB 8093 EN 7

Safety instructions and measures

Referenced standards and regulations

The control valves comply with the requirements of the European Pressure Equipment Direc­tive 2014/68/EU. Valves with a CE marking have a declaration of conformity, which in-

cludes information about the applied conformity assessment procedure. This declaration of

conformity 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 2014/34/EU.

Î For connection to the equipotential bonding system, observe the requirements specied in

section 6.4 of EN60079-14 (VDE0165 Part 1).

Referenced documentation

The following documents apply in addition to these mounting and operating instructions:

− Mounting and operating instructions for mounted actuator, e.g. uEB8310-X for

Type3271 and Type3277 Actuators

− Mounting and operating instructions for mounted valve accessories (positioner, solenoid
valve etc.)

− uAB0100 for tools, tightening torques, and lubricant

− For oxygen service: Manual uH01

8 EB 8093 EN

Safety instructions and measures

1.1 Notes on possible severe personal injury

DANGER

!

Risk of bursting in pressure equipment.

Control valves and pipelines are pressure equipment. Improper opening can lead to

valve components bursting.

Î Before starting any work on the control valve, depressurize all plant sections

concerned as well as the valve.

Î Drain the process medium from all the plant sections concerned as well as the

valve.

Î Wear personal protective equipment.

Risk of injury due to incorrect handling of oxygen or cryogenic gases.

The Type3248 Valve is frequently used for oxygen service or applications with cryo­genic gases. Oxygen is a hazardous substance, which reacts quickly, leading to com­bustion or explosions. Contact with cryogenic gases causes severe frostbite and cold

burns (cryogenic burns). Operating personnel must be trained for these applications.

Unqualied operating personnel expose themselves and others to an increased risk of
injury.

Î Operating personnel must be sufciently trained and be made aware of the dan-

gers occurring in oxygen service and in applications with cryogenic gases.

Î Instructions and information on how to safely handle devices for oxygen service

can be found in the Manual uH01.

All SAMSON staff receives appropriate training before performing any activities in
connection with oxygen service. SAMSON's After-sales Service department also offers
such training courses for service staff to allow them to learn how to handle devices for
the above listed applications correctly and safely.

Tip

EB 8093 EN 9

Safety instructions and 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 injure
hands or ngers if inserted into the valve.

Î Do not insert hands or ngers into the yoke while the valve is in operation.
Î While working on the control valve, disconnect and lock the pneumatic air supply

as well as the control signal.

Risk of personal injury when the actuator vents.

While the valve is operating, the actuator may vent during closed-loop control or when

the valve opens or closes.

Î Install the control valve in such a way that the actuator does not vent at eye level.
Î Use suitable silencers and vent plugs.
Î Wear eye protection when working in close proximity to the control valve.

Risk of personal injury due to preloaded springs.

Valves in combination with pneumatic actuators with preloaded springs are under ten­sion. These control valves with SAMSON pneumatic actuators can be identied by the

long bolts protruding from the bottom of the actuator.

Î Before starting any work on the actuator, relieve the compression from the preload-

ed springs (see associated actuator documentation).

Risk of personal injury due to residual process medium in the valve.

While working on the valve, residual process medium can escape and, depending on
its properties, may lead to personal injury, e.g. cold burns.

Î If possible, drain the process medium from all the plant sections concerned and the

valve.

Î Wear protective clothing, safety gloves, and eyewear.

10 EB 8093 EN

Safety instructions and measures

WARNING

!

Risk of burn injuries due to cold components and pipelines.

Depending on the process medium, valve components and pipelines may get extremely
cold and cause cryogenic burns.

Î Allow components and pipelines to heat up.
Î Wear protective clothing and safety gloves.

1.3 Notes on possible property damage

NOTICE

!

Risk of valve damage due to contamination (e.g. solid particles) in the pipeline.

The plant operator is responsible for cleaning the pipelines in the plant.

Î Flush the pipelines before start-up.
Î Observe the maximum permissible pressure for valve and plant.

Risk of valve damage due to unsuitable medium properties.

The valve is designed for a process medium with dened properties.

Î Only use the process medium specied for sizing the valve.

Risk of leakage and valve damage due to excessively high or low tightening torques.

Observe the specied torques on tightening control valve components. Excessively
tightened torques lead to parts wearing out quicker. Parts that are too loose may cause

leakage.

Î Observe the specied tightening torques (uAB0100).

Risk of valve damage due to the use of unsuitable tools.

Certain tools are required to work on the valve.

Î Only use tools approved by SAMSON (uAB0100).

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.

Î Only use lubricants approved by SAMSON (uAB0100).

EB 8093 EN 11

Safety instructions and measures

12 EB 8093 EN

Markings on the control valve

2 Markings on the control valve

2.1 Valve nameplate

6 8

12 13

10 11

14

15

16

17

1…5

9

SAMSON

20

Fig.1: Valve nameplate

1…5 PED (Pressure Equipment Directive), "Art. 4, Abs. 3"

ID of the notied body, uid group, and category

6 Type designation

8 Material
9 Year of manufacture

10 Valve size:

DIN: DN · ANSI: NPS

11 Pressure rating:

DIN: PN · ANSI: CL

12 Order no. with modication index

For after-sales service orders: AA prex

13 Position in order

For after-sales service orders: conguration ID

14 Flow coefcient:

DIN: K

VS

· ANSI: C

V

15 Characteristic:

%: equal percentage · Lin: linear

16 Seat-plug seal:

ME: metal (see section3.3)

ST: Stellite

®

facing

PT: soft seal with PTFE
17 Seat code (trim material) · On request
20 Country of origin

EB 8093 EN 13

Markings on the control valve

The nameplate is afxed to the valve bonnet
(see Fig.2).

2.2 Actuator nameplate

See associated actuator documentation.

2.3 Material number

The seat and plug of the valves have an arti­cle number written on them. Specifying this

article number, you can contact us to nd out

which material is used. Additionally, a seat
code is used to identify the trim material.

This seat code is specied on the nameplate
(17 on nameplate). For more details on the
nameplate, see section2.1.

2 Valve bonnet

80 Nameplate

80

2

Fig.2: Nameplate on the valve bonnet

14 EB 8093 EN

Design and principle of operation

3 Design and principle of oper-

ation

The Type3248 is available in the following

versions:

− Globe valve with stainless steel body,

DN25 to 150, PN16 to 100 (see Fig.3)

− Angle valve with stainless steel body,

DN25 to 150, PN40 to 100 (see Fig.4)

− Angle valve with aluminum body, DN25
to 150, PN16 to 40 (see Fig.5)

A top-entry design is used for these valves.
As a result, the valve does not need to be re­moved from the pipeline for servicing work.

The seat (4) and plug with plug stem (5) are
installed in the body (1). The plug stem is

screwed to the plug stem with bellows seal

(37) which is, in turn, screwed to the spacer
stem (71). The stem connector clamps
(A26/27) connect the actuator stem (A7) of

the mounted actuator.
In the version with stainless steel body, the

cryogenic extension bonnet is welded onto

the body (1). Its bottom part consists of the

bellows seal and insulated pipe. In the ver­sion with aluminum body, the bellows seal

(22) is screwed to the body. A cover plate
can be welded at a specic angle onto the

pipe or bellows seal. The cover plate serves
as orientation during installation into a cold
box, for example.

The plug stem is sealed by the metal bellows
and the packing (15). The metal bellows pre­vents direct contact of the packing with the
process medium. As a result, the service life
is increased and icing up is prevented. The

test connection at the valve bonnet can be
used to monitor the sealing ability of the bel­lows. The packing consists of a spring-load-

ed PTFE-carbon V-ring packing.
In the PN16 to 40 version, the valve bonnet

(2) is designed as a yoke (see Fig.3). In the
PN63 and 100 version, the valve bonnet (2)

is designed as an intermediate piece. A yoke

(3) is fastened onto the valve bonnet with a
castellated nut (92) (see Fig.4).

A protective cover can be mounted in place
of the valve bonnet and actuator. This reduc­es the overall height of the valve and makes
it easier to transport it. The protective cover
also protects the inside of the bellows seal
against moisture and dirt.

The medium ows 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 compressed. 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 ow rate through the valve.

Actuators

The Type3248 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 springs in the pneumatic actuator are lo-

cated either above or below the diaphragm
depending on the selected fail-safe action

(see section3.1). A change in the signal

pressure acting on the diaphragm causes the

EB 8093 EN 15

Design and principle of operation

Fig.3: Type3248 Globe Valve with

stainless steel body (PN16 to 40)
and with Type3271 Pneumatic

Actuator

Cover plate

1 Body (including cryogenic

extension bonnet)

2 Valve bonnet

4 Seat

5 Plug (with plug stem)

8 Threaded bushing (packing nut)
9 Stem connector nut

10 Lock nut
15 Packing
17 Bonnet gasket
37 Plug stem with metal bellows
41 Bellows nut
42 Test connection
71 Spacer stem
A7 Actuator stem

A26/27 Stem connector clamps

1
4

5

37

41

71

42

15

8

2

17

9

A7

A26/27

10

16 EB 8093 EN

Design and principle of operation

1

4

5

37

41

42

33

15

8

10

9

71

92

32

2

3

22

14
13

1

Fig.4: Type3248 Angle Valve with stainless steel

body (PN100)

Fig.5: Type3248 Angle Valve with aluminum

body (PN16 to 40)

EB 8093 EN 17

Design and principle of operation

plug to move. The actuator size is deter­mined by the diaphragm area.

3.1 Fail-safe positions

The fail-safe position depends on the mount­ed actuator.

Depending on how the compression springs
are arranged in the pneumatic actuator, the
valve has two different fail-safe positions:

Actuator stem extends (FA)

When the signal pressure is reduced or the

air supply fails, the springs move the actua­tor stem downward and close the valve. The
valve opens when the signal pressure is in­creased enough to overcome the force exert­ed by the springs.

Actuator stem retracts (FE)

When the signal pressure is reduced or the

air supply fails, the springs move the actua­tor stem upwards and open the valve. The
valve closes when the signal pressure is in­creased enough to overcome the force exert­ed by the springs.

The actuator's direction of action can be re­versed, if required. Refer to the mounting
and operating instructions of the pneumatic
actuator:

uEB8310‑X for Type3271 and Type3277

3.2 Versions

Larger nominal sizes

The Type3248 Valve is available up to nom­inal size DN200.

Actuators

In these instructions, the preferable combina­tion with a Type3271 or Type3277 Pneu­matic 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.

Î Observe the maximum permissible actu-

ator force.

Tip

1 Body
2 Valve bonnet
3 Yoke

4 Seat

5 Plug (with plug stem)

8 Threaded bushing (packing

nut)

9 Stem connector nut

10 Lock nut
13 Stud bolt
14 Body nut
15 Packing
17 Bonnet gasket
22 Bellows seal
32 Bolt
33 Nut

37 Plug stem with metal bellows
41 Bellows nut
42 Test connection
71 Spacer stem
92 Castellated nut

18 EB 8093 EN

Design and principle of operation

If the travel range of the actuator is larger
than the travel range of the valve, the spring
assembly in the actuator must be preloaded
so that the travel ranges match. See associ­ated actuator documentation.

The basic pneumatic actuator can be re­placed by a pneumatic actuator with addi­tional handwheel.

3.3 Technical data

The nameplates on the valve and actuator
provide information on the control valve

version. See section2.1 and the actuator

documentation.

More information is available in Data Sheet

uT8093.

Compliance

The Type3248 Valve bears both the CE and
EAC marks of conformity.

Temperature range

The Type3248 Valve is designed for a
temperature range from –196 to +65°C.

The use of an extended bellows seal extends

the temperature range down to –273°C.

Leakage class

Depending on the version, the following

leakage class according to IEC60534-4

applies:

Seal (16 on nameplate) Leakage class

Metal seal (ME) IV

High-performance metal

seal, e.g. Stellite® facing
(ST)

V

PTFE soft seal (PT) VI

Noise emission

SAMSON is unable to make general
statements 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 and Part8-4 or
VDMA24422 (edition 89).

Risk of hearing loss or deafness due to loud
noise.
Wear hearing protection when working near
the valve.

Dimensions and weights

Table1 to Table5 provide a summary of the

dimensions of the various versions of

Type3248 Valve. Table6 lists the weights of
the various versions of Type3248 Valve. The

lengths and heights in the dimension dia-

grams are shown on page22.

Note

Note

WARNING

!

EB 8093 EN 19

Design and principle of operation

Height H7 is the minimum clearance for ser­vice work. The actuator dimensions must also
be observed. The largest value applies.
Height H1 and the specied weights are ref­erence values. The exact dimensions and
weights depend on various factors, e.g. ac­tuator size and overall height.

Note

Table1: Dimensions of globe valve with stainless steel body, PN16 to 40

Valve DN 25 40 50 80 100 150

L mm 210 251 286 337 394 508
H1 mm 854 864 864 1052 1147.5 1188.5
H2 mm 44 71 71 93 111 174
H4 mm 600 600 600 700 800 800
H5 mm 708 714 714 824 933.5 974.5
H7 mm 1050 900 900 900 1100 1100
Ød mm 282 282 282 282 282 282
Welding ends/

pipe connection

1)

Ø33.7

x 2.3

Ø48.3

x2.6

Ø60.3

x 3.2

Ø88.9

x 4

Ø114.3

x 5

Ø168.3

x 5.6

1)

Deviating dimensions on request

20 EB 8093 EN

Design and principle of operation

Table2: Dimensions of globe valve with stainless steel body, PN63 and 100

Valve DN 25 40 50 80 100 150

L mm 210 251 286 337 394 508
H1

1)

mm 822 817 817 832 984 1298
H2 mm 44 71 71 93 111 174
H4

2)

mm 600 600 600 600 650 800
H5 mm 734 734 734 734 786 923
H7 mm 1050 900 900 900 1100 1100
Ød mm 282 282 282 282 282 282
Welding ends/

pipe connection

2)

Ø33.7

x 3.2

Ø48.3

x 3.6

Ø60.3

x 4

Ø88.9

x 5.6

Ø114.3

x 6.3

Ø168.3

x 7.1

1)

Dimension H1+85mm applies when 1400-120cm² actuators are used

2)

Deviating dimensions on request

Table3: Dimensions of angle valve with stainless steel body, PN40

Valve DN 25 40 50 80 100 150

L mm 98 133 133 159 184 236
H1 mm 830 845 845 1017 1108 1101
H4 mm 600 600 600 650 750 750
H5 mm 684 695 695 788 893 887
H7 mm 1050 900 900 900 1100 1100
Ød mm 282 282 282 282 282 282
Welding ends/

pipe connection

Ø33.7

x 2.3

Ø48.3

x 2.6

Ø60.3

x 3.2

Ø88.9

x 4

Ø114.3

x 5

Ø168.3

x 5.6

EB 8093 EN 21

Design and principle of operation

Table4: Dimensions of angle valve with stainless steel body, PN100

Valve DN 25 40 50 80 100 150

L mm 98 133 133 159 184 236
H1

1)

mm 798 798 798 795.5 943 1210

H4

2)

mm 400/600 400/600 400/600 400/600 500/600 550/600

H5

2)

mm 510/710 515/715 515/715 498/698 645/745 649/699
H7 mm 1050 900 900 900 1100 1100
Ød mm 282 282 282 282 282 282
Welding ends/

pipe connection

Ø33.7

x 3.2

Ø48.3

x3.6

Ø60.3

x 4

Ø88.9

x5.6

Ø114.3

x 6.3

Ø168.3

x 7.1

1)

Dimension H1+85mm applies when 1400-120cm² actuators are used

2)

Different overall height possible

Table5: Dimensions of angle valve in stainless steel version with aluminum body, PN16 to
40

1)

Valve DN 25 40 50 80 100 150

L mm

98 133 133 159 184 236

H1 mm 825 827 827 1035 1120 1149
H4 mm 600 600 600 700 800 800
H5 mm 679 677 677 807 906 935
H7 mm 1050 900 900 900 1100 1100
Ød mm 282 282 282 282 282 282
Welding ends/

pipe connection

Ø35

x 3.5

Ø50

x4

Ø60

x4

Ø89

x5

Ø114

x6

Ø162

x8

1)

Higher nominal pressures on request

22 EB 8093 EN

Design and principle of operation

Dimensional drawings

H7

h=30

H2 H1

Ød

L

t=3

t=3

H4

H5

t=3

t=3

L

H4

H5

H1

h=30

Ød

L

H7

Globe valve with stainless steel body Angle valve with stainless steel body

H7

t=3

t=3

H4

H5

Ød

h=30

H1

L

L

Angle valve with aluminum body

EB 8093 EN 23

Design and principle of operation

Table6: Weights of Type3248 Valve · Without actuator

Valve DN 25 40 50 80 100 150

Globe valve with stainless steel body, PN16 to 40

Weight kg 16 26 26 55 96 148

Globe valve with stainless steel body, PN63 and 100

Weight kg 17 30 30 59 106 186

Angle valve with stainless steel body, PN40

Weight kg 16.5 27 27 57 98 127

Angle valve with stainless steel body, PN100

Weight kg 18 31 31 61 107 186

Angle valve in stainless steel version with aluminum body, PN16 to 40

Weight kg 18 37 37 68 107 130.5

Refer to the following data sheets for dimensions and weights of the SAMSON pneumatic
actuators:

uT8310‑1 for Type3271 and Type3277 Actuators up to 750cm² actuator area
uT8310‑2 for Type3271 Actuator with 1000cm² actuator area and larger
uT8310‑3 for Type3271 Actuator with 1400‑60cm² actuator area

Note

24 EB 8093 EN

Measures for preparation

4 Measures for preparation

After receiving the shipment, proceed as fol­lows:

1. Check the scope of delivery. Compare

the shipment received against the deliv­ery note.

2. Check the shipment for transportation
damage. Report any damage to

SAMSON and the forwarding agent (re­fer to delivery note).

4.1 Unpacking

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 tted on the valve's inlet

and outlet prevent foreign particles from en­tering the valve and damaging it.
Do not remove the protective caps until im­mediately before installing the valve into the
pipeline.

4.2 Transporting and lifting

Hazard due to suspended loads falling.
Stay clear of suspended or moving loads.

Risk of lifting equipment tipping and risk of
damage to lifting accessories due to exceed­ing the rated lifting capacity.

− Only use approved lifting equipment and
accessories whose minimum lifting capaci­ty is higher than the weight of the valve

(including actuator, if applicable).

− Refer to section3.3 and the corresponding
data sheets for the weights.

Risk of personal injury due to control valve
tipping.

− Observe the valve's center of gravity.

− Secure the valve against tipping over or
turning.

Note

NOTICE

!

DANGER

!

WARNING

!

WARNING

!

EB 8093 EN 25

Measures for preparation

Risk of valve damage due to incorrectly at­tached slings.
The welded-on lifting eyelet on SAMSON
actuators is only intended for mounting and
removing 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 to the
actuator, handwheel or any other parts.

− Observe lifting instructions (see sec-

tion4.2.2).

SAMSON's After-sales Service department
can provide more detailed transport and lift­ing instructions on request.

4.2.1 Transporting

The control valve can be transported using
lifting equipment (e.g. crane or forklift).

Î Leave the control valve in its transport

container or on the pallet to transport it.

Î Observe the transport instructions.

Transport instructions

− Protect the control valve against external
inuences (e.g. impact).

− Do not damage the corrosion protection

(paint, surface coatings). Repair any

damage immediately.

− Protect the control valve against moisture
and dirt.

− The permissible transportation tempera-

ture of standard control valves is –20 to
+65°C.

Contact SAMSON's After-sales Service de­partment for the transportation temperatures
of other valve versions.

NOTICE

!

Tip

Note

26 EB 8093 EN

Measures for preparation

Fig.6: Lifting using one hook

4.2.2 Lifting

To install a large valve into the pipeline, use
lifting 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.

− Prevent the control valve from tilting or
tipping.

− Do not leave loads suspended when in-
terrupting work for longer periods of
time.

− We recommend using a hook with safety

latch (see Fig.9). The safety latch prevents

the slings from slipping during lifting and
transporting.

− Angle valves with aluminum bodies have
threaded holes in the body in which swivel
lifting hooks can be screwed for lifting the
control valve.

Tip

EB 8093 EN 27

Measures for preparation

Lifting with the actuator mounted

The control valve can be lifted in the hori-

zontal position either using one hook (Fig.6)
or using several hooks on a beam (Fig.7).

1. Attach one sling to the valve body, cryo-

genic extension bonnet, and valve bon­net or yoke as well as to the rigging
equipment (e.g. hook) of the crane or

forklift (see Fig.6).

2. With beam, DN100 and larger: attach

additional sling to support the valve at
the body.

3. Carefully lift the control valve. Check

whether the lifting equipment and acces­sories can bear the weight.

4. Move the control valve at an even pace
to the site of installation.

5. Install the valve into the pipeline (see sec-
tion5.1.3).

6. After installation in the pipeline, check

whether the weld seams hold.

7. Remove slings.

Fig.7: Lifting using a beam

28 EB 8093 EN

Measures for preparation

Lifting with the protective cover mounted

1. Attach two slings to the cryogenic exten­sion bonnet and to the rigging equip­ment (e.g. hook) of the crane or forklift

(see Fig.8).

2. DN100 and larger: attach additional

sling to support the valve at the body.

3. Proceed as described in Lifting with the
actuator mounted, steps3 to 7.

Lifting the control valve with mounted actu­ator in the upright position

Optionally, the valve can be lifted in the up-

right position (see Fig.9).

On lifting the control valve in the upright po­sition, make sure the following conditions
are met:

− 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 actuators with

an actuator area of 700cm² or larger.

The sling only protects the control valve
from tilting while being lifted. Before lift­ing the control valve, tighten the sling.

Fig.8: Lifting using a beam when the protective cover is mounted

EB 8093 EN 29

Measures for preparation

Fig.9: Lifting points on the control valve: globe valve (left) and angle valve (right)

30 EB 8093 EN

Measures for preparation

For lifting in the upright position, proceed as
follows:

1. 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.9).

2. Secure the slings attached to the body

against slipping using a connector.

3. 700cm² and larger: attach another
sling to the lifting eyelet on the actuator
and to the rigging equipment.

4. Carefully lift the control valve. Check
whether the lifting equipment and acces­sories can bear the weight.

5. Move the control valve at an even pace
to the site of installation.

6. Install the valve into the pipeline (see sec-
tion5.1.3).

7. After installation in the pipeline, check

whether the weld seams hold.

8. Remove connector and slings.

4.3 Storage

Risk of valve damage due to improper stor­age.

− Observe storage instructions.

− Avoid long storage times.

− Contact SAMSON in case of different stor-
age conditions or long storage periods.

We recommend regularly checking the con­trol valve and the prevailing storage condi­tions during long storage periods.

Storage instructions

− Protect the control valve against external

inuences (e.g. impact).

− Do not damage the corrosion protection

(paint, surface coatings). Repair any

damage immediately.

− Protect the control valve against moisture

and dirt. Store it at a relative humidity of

less than 75%. In damp spaces, prevent

condensation. If necessary, use a drying
agent or heating.

− 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.

NOTICE

!

Note

EB 8093 EN 31

Measures for preparation

Contact SAMSON's After-sales Service de­partment for the storage temperatures of oth­er valve versions.

− Do not place any objects on the control
valve.

Special storage instructions for elastomers

Elastomer, e.g. actuator diaphragm

− To keep elastomers in shape and to pre-
vent cracking, do not bend them or hang
them up.

− We recommend a storage temperature of

15°C for elastomers.

− Store elastomers away from lubricants,
chemicals, solutions, and fuels.

SAMSON's After-sales Service department
can provide more detailed storage instruc­tions on request.

4.4 Preparation for installation

Proceed as follows:

Î Flush the pipelines.

The plant operator is responsible for clean­ing the pipelines in the plant.

Î Check the valve to make sure it is clean.
Î Check the valve for damage.
Î Check to make sure that the type desig-

nation, valve size, material, pressure rat­ing, and temperature range of the valve

match the plant conditions (size and

pressure rating of the pipeline, medium
temperature etc.).

Î Check any mounted pressure gauges to

make sure they function.

Î When the valve and actuator are al-

ready assembled, check the tightening

torques of the bolted joints (uAB0100).
Components may loosen during trans-

port.

Note

Tip

Note

32 EB 8093 EN

Mounting and start-up

5 Mounting and start-up

SAMSON valves are delivered ready for
use. In some cases, the valve is delivered
with a protective cover mounted. This can be
removed either before or after the valve is in-

stalled into the pipeline (see section5.2). The

procedure to mount and start up the valve
are described in following.

Risk of valve damage due to excessively high
or low tightening torques.

Observe the specied torques on tightening
control valve components. Excessively tight-

ened torques lead to parts wearing out
quicker. Parts that are too loose may cause
leakage.

Observe the specied tightening torques

(uAB0100).

Risk of valve damage due to the use of un­suitable tools.
Only use tools approved by SAMSON
(uAB0100).

5.1 Installing the valve into the
pipeline

5.1.1 Checking the installation

conditions

Pipeline routing

The inlet and outlet lengths vary depending
on the process medium. To ensure the control
valve functions properly, follow the installa­tion instructions given below:

Î Observe the inlet and outlet lengths (see

Table7). Contact SAMSON if the valve

conditions or state of the medium process
deviate.

Î Install the valve free of stress and with the

least amount of vibrations as possible. If
necessary, attach supports to the valve.

Î Install the valve allowing sufcient space

to remove the actuator and valve or to
perform service and repair work on
them.

Mounting position

We recommend mounting the valve at an
angle between 15 and 25° to the horizontal

plane.

Î Contact SAMSON if the mounting posi-

tion is not as specied above.

Support or suspension

Depending on the valve version and mount­ing position, the control valve and pipeline
must be supported or suspended. The plant
engineering company is responsible in this
case.

NOTICE

!

NOTICE

!

EB 8093 EN 33

Mounting and start-up

Table7: Inlet and outlet lengths

Q

a x DN b x DN

State of process
medium

Valve conditions Inlet length a Outlet length b

Gas

Ma≤0.3 2 4

0.3≤Ma≤0.7 2 10

Liquid

Free of cavitation/w<10m/s 2 4

Cavitation producing noise/w≤3m/s 2 4

Cavitation producing noise/3<w<5m/s 2 10

Critical cavitation/w≤3m/s 2 10

Critical cavitation/3<w<5m/s 2 20

Flashing – 2 20

Q Flow rate

a Inlet length
b Outlet length

Premature wear and leakage due to insuf­cient support or suspension.
In the following versions, the control valve
must be supported or suspended:

− For versions with side-mounted handwheel

which are installed at an angle of <45° to

the horizontal plane
Attach a suitable support or suspension to
the valve.

Î Avoid supporting or suspending the

valve in the area around bellows nut

(41).

Vent plugs

Vent plugs are screwed into the exhaust air

ports of pneumatic devices. They ensure that
any exhaust air that forms can be vented to
the atmosphere (to avoid excess pressure in
the device). Furthermore, the vent plugs al­low air intake to prevent a vacuum from
forming in the device.

Î Locate the vent plug on the opposite side

to the workplace of operating personnel.

Î On mounting valve accessories, make

sure that they can be operated from the
workplace of the operating personnel.

NOTICE

!

34 EB 8093 EN

Mounting and start-up

The workplace of operating personnel is the
location from which the valve, actuator, and
any mounted valve accessories can be ac­cessed to operate them.

5.1.2 Additional ttings

Insulation

Control valves with cover plates can be insu­lated up to the cover plate. Control valves

without cover plates must only be insulated

up to the top of the body ange.

Safety guard

To reduce the crush hazard arising from

moving parts (actuator and plug stem), a
safety guard can be installed.

Test connection

The test connection at the valve bonnet can
be used to monitor the sealing ability of the

bellows. Particularly for liquids and vapors,

we recommend installing a suitable leakage
indicator (e.g. a contact pressure gauge, an
outlet to an open vessel or an inspection
glass).

5.1.3 Installing the control
valve

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 equip­ment to the site of installation (see sec-

tion4.2.2). Observe the ow direction

through the valve. The arrow on the

valve indicates the direction of ow.

4. Completely retract the actuator stem to
protect the plug from sparks during weld­ing:

With mounted protective cover: turn the

adjustment bolt (95.2) clockwise.

With mounted actuator, "stem extends"

direction of action: apply a signal pres­sure to the actuator.

With mounted actuator, "stem retracts"

direction of action: the valve is open
without any signal pressure being ap­plied.

5. Weld the valve free of stress into the

pipeline.

6. Depending on the eld 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 in­stalled.

Risk of valve damage due to a sudden pres­sure increase and resulting high ow veloci­ties.
Slowly open the shut-off valve in the pipeline
during start-up.

8. Check the valve to ensure it functions
properly. See section5.4.

Note

NOTICE

!

EB 8093 EN 35

Mounting and start-up

5.2 Removing the protective
cover

To keep the overall height of valves for cold­box applications during transportation, the
actuator and valve body can be removed
from the body (cryogenic extension bonnet).
In this case, the plug stem with bellows seal

(37) is secured by a protective cover. The

valve can be installed into the pipeline with
the protective cover still mounted. The protec­tive cover can remain mounted on the valve

also during a pressure test (see section5.4).
Upon delivery with the protective cover, the

valve is open: the thread of the plug stem

with bellows seal (37) is completely screwed
into the adjustment bolt (95.2).

Moving the plug stem

Î To close the valve, turn the adjustment

bolt (95.2) counterclockwise.

Î To open the valve, turn the adjustment

bolt (95.2) clockwise.

A plate on the protective cover indicates the

turning direction (see Fig.10).

Removing the protective cover

1. Remove nuts (33) and washers (95.9).

2. Turn the adjustment bolt (95.2) counter-

clockwise. The plug is lowered and the
protective cover is lifted off the body.

3. As soon as the end of the thread is
reached, remove the protective cover
from the body.

The nuts (33) are required to mount the valve
bonnet. The washers (95.9) are no longer

required.

Mounting the valve bonnet

For PN63 and 100 versions, mount the
valve bonnet (2) together with the yoke (3).

1. Insert a new gasket (17) into the body
(1).

2. Carefully place the valve bonnet (2) to­gether with the spacer stem (71) on the
valve body (1). Place the spacer stem
over the thread of the plug stem (37) and

tighten by hand. Make sure that the posi­tion of the stem connector nut (9) and

Tip

Note

Note

Fig.10: Plate indicating the

turning direction of the
adjustment bolt

36 EB 8093 EN

Mounting and start-up

33

9

10

3

2

71

37

17

1

32

8

92

F

M

A

42
43

95.2

95.3

95.4

95.9

95.1

37

95.5

95.6

95.7

33

32

1 Body
2 Valve bonnet

3 Yo ke

9 Stem connector nut

10 Lock nut
17 Bonnet gasket
32 Bolt
33 Nut
37 Plug stem with metal

bellows

42 Screw plug (test

connection)

43 Gasket
71 Spacer stem

95.1 Cover of protective cover

95.2 Stud/adjustment bolt

95.3 Axial retaining ring

95.4 O-ring

95.5 Gasket

95.6 Screw plug (test

connection)

95.7 O-ring (glued)

95.9 Washer (spacer sleeve)

9

10

2

71

37

17

1

8

PN16 to 40

PN63 and 100

Fig.11: Protective cover and valve bonnet

EB 8093 EN 37

Mounting and start-up

lock nut (10) on the spacer stem is not

changed.

3. Fasten the valve bonnet (2) using the nuts
(33) and bolts (32). Tighten the nuts

gradually in a criss-cross pattern. Ob­serve tightening torques.

4. Tighten the spacer stem (71) and plug

stem (37) over the stem connector nut

(9). Observe tightening torques.

5. Mount actuator. See associated actuator
documentation.

6. In case the position of the stem connector
nut and lock nut has been changed

during mounting (step2): adjust lower or

upper signal bench range. See associat­ed actuator documentation.

5.3 Mounting the actuator onto

the valve

Proceed as described in the actuator docu­mentation if the valve and actuator have not
been assembled by SAMSON.

If a protective cover is mounted, rst remove

it and mount the valve bonnet (see sec-

tion5.2).

Versions with V-port plug

Each V-port plug has three V-shaped ports.
Depending on the valve size, the size of the
symmetrically arranged V-shaped ports var­ies. The process medium in the valve ows
through the V-shaped ports as soon as the

plug is lifted out of the seat (i.e. the valve
opens).

1. Before mounting the actuator, determine
which V-shaped port is uncovered rst

when the plug is lifted out of the seat.

Usually, this is the largest V-shaped port.

2. On mounting the actuator, make sure
that the V-shaped port uncovered rst

faces toward the valve outlet.

Risk of damage to the wall of the valve body
due to incorrectly diverted jet stream.
The process medium cannot ow unob­structed through the valve when the V-port
plug has been installed incorrectly. This will
result in the process medium hitting the body
wall, which may lead to severe valve dam­age.
Make sure the V-port plug is installed
correctly.

− Remove the mounted actuator before
mounting the other actuator (see associat-

ed actuator documentation).

− Preloading the actuator springs increases
the thrust of a pneumatic actuator and re­duces the travel range of the actuator (see

associated actuator documentation).

Tip

NOTICE

!

Information

38 EB 8093 EN

Mounting and start-up

5.4 Quick check

SAMSON valves are delivered ready for
use. To test the valve's ability to function, the
following quick checks can be performed:

Tight shut-off

1. Close the valve.

2. Slowly open the shut-off valve in the

pipeline.

Risk of valve damage due to a sudden pres­sure increase and resulting high ow veloci­ties.
Slowly open the shut-off valve in the pipeline
during start-up.

3. Check the valve for leakage (visual in­spection).

Travel motion

The movement of the actuator stem must be
linear and smooth.

Î Open and close the valve, observing the

movement of the actuator stem.

Î Apply the maximum and minimum con-

trol signals to check the end positions of
the valve.

Î Check the travel reading at the travel in-

dicator scale.

Fail-safe position

Î Shut off the signal pressure line.
Î Check whether the valve moves to the

fail-safe position.

Pressure test with mounted protective cover

With a mounted protective cover, perform

the test pressure with an open valve as well
as with a closed valve.

1. To open the valve, turn the adjustment
bolt (95.2) clockwise.

2. Perform the pressure test. Observe the

maximum permissible pressure for valve
and plant.

3. To close the valve, turn the adjustment
bolt (95.2) counterclockwise.

4. Perform the pressure test. Observe the
maximum permissible pressure for valve
and plant.

The plant operator is responsible for per­forming the pressure test. SAMSON's Af­ter-sales Service department can support you
to plan and perform a pressure test for your
plant.

Pressure test with mounted actuator

During the pressure test, make sure the fol­lowing conditions are met:

− Retract the plug stem to open the valve.

− Observe the maximum permissible pres-
sure for valve and plant.

NOTICE

!

Note

EB 8093 EN 39

Mounting and start-up

The plant operator is responsible for
performing the pressure test. SAMSON's
After-sales Service department can support
you to plan and perform a pressure test for
your plant.

Note

40 EB 8093 EN

Operation

6 Operation

Immediately after completing mounting and

start-up (see section5), the valve is ready for

use.

Crush hazard arising from moving parts

(actuator and plug stem).
Do not insert hands or ngers into the yoke

while the valve is in operation.

Risk of personal injury when the actuator
vents.
Wear eye protection when working in close
proximity to the control valve.

Risk of burn injuries due to cold components
and pipelines.
Depending on the process medium, valve
components and pipelines may get extremely
cold and cause cryogenic burns.
Wear protective clothing and safety gloves.

Operation disturbed by a blocked actuator
or 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 tted with actuators with a handwheel

can be manually closed or opened in case of
supply air failure.

Î For normal closed-loop operation, move

the handwheel to the neutral position.

WARNING

!

WARNING

!

WARNING

!

NOTICE

!

EB 8093 EN 41

42 EB 8093 EN

Servicing

7 Servicing

The control valve is subject to normal wear,

especially at the seat, plug, and packing.
Depending on the operating conditions,
check the valve at regular intervals to pre­vent possible failure before it can occur.

SAMSON's After-sales Service department
can support you to draw up an inspection
plan for your plant.

We recommend removing the valve from the

pipeline for service or repair work (see sec-

tion9.2).

Risk of bursting in pressure equipment.
Control valves and pipelines are pressure
equipment. Improper opening can lead to
bursting of the valve.

− Before starting any work on the control
valve, depressurize all plant sections con­cerned as well as the valve.

− Drain the process medium from all the
plant sections concerned as well as the
valve.

− Wear personal protective equipment.

Risk of personal injury due to residual pro­cess medium in the valve.
While working on the valve, residual process
medium can escape and, depending on its
properties, may lead to personal injury, e.g.

(chemical) burns.

Wear protective clothing, safety gloves, and
eyewear.

Risk of burn injuries due to cold components
and pipelines.
Depending on the process medium, valve
components and pipelines may get extremely
cold and cause cryogenic burns.

− Allow components and pipelines to cool
down or heat up.

− Wear protective clothing and safety gloves.

Risk of valve damage due to incorrect servic­ing or repair.
Service and repair work must only be per­formed by trained staff.

Risk of valve damage due to excessively high
or low tightening torques.

Observe the specied torques on tightening
control valve components. Excessively tight-

ened torques lead to parts wearing out
quicker. Parts that are too loose may cause
leakage.

Observe the specied tightening torques
(uAB0100).

Tip

DANGER

!

WARNING

!

WARNING

!

NOTICE

!

NOTICE

!

EB 8093 EN 43

Servicing

Risk of valve damage due to the use of un­suitable tools.
Only use tools approved by SAMSON
(uAB0100).

Risk of valve damage due to the use of un­suitable lubricants.
Only use lubricants approved by SAMSON
(uAB0100).

The control valve was checked by SAMSON
before it left the factory.

− Certain test results (seat leakage and leak
test) certied by SAMSON lose their validi­ty when the valve body or actuator hous­ing is opened.

− The product warranty becomes void if ser-
vice or repair work not described in these
instructions is performed without prior
agreement by SAMSON's After-sales Ser­vice department.

− Only use original spare parts by
SAMSON, which comply with the original

specications.

7.1 Replacing the gasket

7.1.1 Globe or angle valve,

PN16 to 40

1. Remove the actuator from the valve. See

associated actuator documentation.

2. Undo the nuts (33) gradually in a criss­cross pattern. Remove the nuts and bolts
(32).

3. Carefully lift the valve bonnet (2) off the
valve body (1) over the spacer stem (71).

4. Remove the gasket (17). Carefully clean
the sealing faces in the valve bonnet (2)
and on the body (1).

5. Insert a new gasket (17) into the body
(1).

6. Carefully place the valve bonnet (2) on
the valve body (1) over the spacer stem
(71).

7. Fasten the valve bonnet (2) using the nuts
(33) and bolts (32). Tighten the nuts

gradually in a criss-cross pattern. Ob­serve tightening torques.

8. Mount actuator. See associated actuator
documentation.

9. Adjust lower or upper signal bench
range. See associated actuator docu­mentation.

NOTICE

!

NOTICE

!

Note

44 EB 8093 EN

Servicing

33

9

10

3

2

71

37

17

1

32

8

92

1 Body
2 Valve bonnet
3 Yoke

8 Threaded bushing

(packing nut)

9 Stem connector nut

10 Lock nut
17 Bonnet gasket
32 Bolt
33 Nut

37 Plug stem with metal

bellows

71 Spacer stem
92 Castellated nut

9

10

2

71

37

17

1

8

Fig.12: Valve bonnet: PN16 to 40 (left) · PN63 and 100 (right)

7.1.2 Globe or angle valve,

PN63 and 100

1. Remove the actuator from the valve. See

associated actuator documentation.

2. Unthread the stem connector nut (9) and
lock nut (10) from the spacer stem (71).

3. Loosen the threaded bushing (8) to re-

lieve the tension from the packing.

The threaded bushing does not need to be
completely unscrewed to replace the gasket.

4. Undo the nuts (33) gradually in a criss­cross pattern. Remove the nuts and bolts
(32).

5. Carefully lift the valve bonnet (2) togeth­er with the yoke (3) off the valve body
(1) and the spacer stem (71).

6. Remove the gasket (17). Carefully clean
the sealing faces in the valve bonnet (2)
and on the body (1).

7. Insert a new gasket (17) into the body
(1).

Note

EB 8093 EN 45

Servicing

8. Carefully place the valve bonnet (2) to­gether with the yoke (3) on the valve
body (1) over the spacer stem (71).

9. Fasten the valve bonnet (2) using the nuts
(33) and bolts (32). Tighten the nuts

gradually in a criss-cross pattern. Ob­serve tightening torques.

10. Tighten the threaded bushing (8). Ob­serve tightening torques.

11. Loosely screw the lock nut (10) and stem

connector nut (9) onto the spacer stem

(71).

12. Mount actuator. See associated actuator

documentation.

13. Adjust lower or upper signal bench

range. See associated actuator docu­mentation.

7.2 Replacing the packing

Risk of control valve damage due to incorrect
service or repair.
The packing can only be replaced when all
the following conditions are met:

− Nominal size of the valve is ≤DN150.

− The standard or FormD (for oxygen) pack-
ing is installed in the valve.

To replace the packing in other valve ver­sions, contact SAMSON's After-sales Service
department.

7.2.1 Globe or angle valve,

PN16 to 40

1. Remove the actuator from the valve. See

associated actuator documentation.

2. Unthread the stem connector nut (9) and
lock nut (10) from the spacer stem (71).

3. Unscrew the threaded bushing (8).

4. Undo the nuts (33) gradually in a criss­cross pattern. Remove the nuts and bolts
(32).

5. Carefully lift the valve bonnet (2) over the
spacer stem (71).

6. Pull all the packing parts out of the pack-

ing chamber using a suitable tool.

7. Renew the damaged parts and carefully

clean the packing chamber.

8. Replace gasket as described in sec-

tion7.1.1.

9. Apply a suitable lubricant to all the pack­ing parts.

10. Carefully slide the packing parts over the
spacer stem (71) into the packing cham-

ber using a suitable tool. Observe the

proper sequence (see Fig.13).

11. Carefully place the valve bonnet (2) on
the valve body (1) over the spacer stem
(71).

12. Fasten the valve bonnet (2) using the nuts
(33) and bolts (32). Tighten the nuts

gradually in a criss-cross pattern. Ob­serve tightening torques.

13. Screw in the threaded bushing (8) and
tighten it. Observe tightening torques.

NOTICE

!

46 EB 8093 EN

Servicing

14. Loosely screw the lock nut (10) and stem

connector nut (9) onto the spacer stem

(71).

15. Mount actuator. See associated actuator

documentation.

16. Adjust lower or upper signal bench

range. See associated actuator docu­mentation.

7.2.2 Globe or angle valve,

PN63 and 100

1. Remove the actuator from the valve. See

associated actuator documentation.

2. Unscrew the castellated nut (92) and lift
the yoke (3) off the valve bonnet (2).

3. Unthread the stem connector nut (9) and
lock nut (10) from the spacer stem (71).

4. Unscrew the threaded bushing (8).

5. Pull all the packing parts out of the pack-

ing chamber using a suitable tool.

6. Renew the damaged parts and carefully

clean the packing chamber.

7. Apply a suitable lubricant to all the pack­ing parts.

8. Carefully slide the packing parts over the
spacer stem (71) into the packing cham­ber using a suitable tool. Observe the

proper sequence (see Fig.13).

9. Screw in the threaded bushing (8) and
tighten it. Observe tightening torques.

10. Place yoke (3) on the valve bonnet (2)

and fasten tight using the castellated nut

(92).

8

2

16
12

11

71

15

8

2

16
12

11

71

15

19

2 Valve bonnet

8 Threaded bushing

11 Spring

12 Washer
15 Packing
16 V-ring packing

19 Bushing
71 Spacer stem

Fig.13: Packing

EB 8093 EN 47

Servicing

11. Loosely screw the lock nut (10) and stem
connector nut (9) onto the plug stem (5).

12. Mount actuator. See associated actuator

documentation.

13. Adjust lower or upper signal bench

range. See associated actuator docu­mentation.

7.3 Replacing the seat and

plug

Risk of control valve damage due to incorrect
service or repair.

To replace seat and plug in the Type3248

Valve, contact SAMSON's After-sales Ser­vice department.

7.4 Replacing the bellows seal

Risk of control valve damage due to incorrect
service or repair.

To replace the bellows seal in the Type3248

Valve, contact SAMSON's After-sales Ser­vice department.

7.5 Preparation for return ship-

ment

Defective valves can be returned to
SAMSON for repair.

Proceed as follows to return valves to

SAMSON:

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 uwww.samson.de > Services

> Check lists for after sales service >
Declaration on Contamination.

4. Send the valve together with the lled-in
form to your nearest SAMSON subsidi­ary. SAMSON subsidiaries are listed on
our website at uwww.samson.de >

Contact.

7.6 Ordering spare parts and

operating supplies

Contact your nearest SAMSON subsidiary

or the SAMSON After-sales Service depart­ment for information on spare parts, lubri­cants, and tools.

Spare parts

Details on spare parts are available on re­quest.

Lubricant

Details on suitable lubricants can be found in
the document uAB0100.

Tools

Details on suitable tools can be found in the
document uAB0100.

NOTICE

!

NOTICE

!

48 EB 8093 EN

Malfunctions

8 Malfunctions

Depending on the operating conditions, check the valve at certain intervals to prevent possi­ble failure before it can occur. Operators are responsible for drawing up an inspection plan.

SAMSON's After-sales Service department can support you to draw up an inspection plan
for your plant.

8.1 Troubleshooting

Malfunction Possible reasons Recommended action

Actuator or plug stem does not
move on demand.

Actuator is blocked. Check attachment.

Unblock the actuator.

Signal pressure too low Check the signal pressure.

Check the signal pressure line for

leakage.

Actuator or plug stem does not
move through the whole range.

Signal pressure too low Check the signal pressure.

Check the signal pressure line for

leakage.

Increased ow through closed

valve (seat leakage)

Dirt or other foreign particles
deposited between the seat and
plug.

Shut off the section of the pipe-

line and ush the valve.

Valve trim, particularly with soft

seat, is worn.

Contact SAMSON's After-sales

Service department.

The valve leaks to the atmo­sphere (fugitive emissions).

The packing and metal bellows
are defective.

Contact SAMSON's After-sales

Service department.

Flange joint not tight. Check the ange joint.
Gasket worn out. Replace bonnet gasket. See

section7.1) or contact

SAMSON's After-sales Service
department.

Icing up of the packing chamber. Metal bellows is defective. Contact SAMSON's After-sales

Service department.

Tip

EB 8093 EN 49

Malfunctions

Contact SAMSON's After-sales Service department for malfunctions not listed in the table.

Note

8.2 Emergency action

Upon supply air or control signal failure, the

valve moves to its fail-safe position (see sec-

tion3.1).

The plant operator is responsible for emer­gency action 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 owing

through the valve.

2. Check the valve for damage. If neces­sary, contact SAMSON's After-sales Ser­vice department.

Putting the valve back into operation after
a malfunction

Î Slowly open the shut-off valves. Allow

the process medium to slowly ow into

the valve.

50 EB 8093 EN

Decommissioning and disassembly

9 Decommissioning and disas-

sembly

Risk of bursting in pressure equipment.
Control valves and pipelines are pressure
equipment. Improper opening can lead to
bursting of the valve.

− Before starting any work on the control
valve, depressurize all plant sections con­cerned as well as the valve.

− Drain the process medium from all the
plant sections concerned as well as the
valve.

− Wear personal protective equipment.

Risk of personal injury due to residual pro­cess medium in the valve.
While working on the valve, residual process
medium can escape and, depending on its
properties, may lead to personal injury, e.g.

(chemical) burns.

Wear protective clothing, safety gloves, and
eyewear.

Risk of burn injuries due to cold components
and pipelines.
Depending on the process medium, valve
components and pipelines may get extremely
cold and cause cryogenic burns.

− Allow components and pipelines to cool
down or heat up.

− Wear protective clothing and safety gloves.

9.1 Decommissioning

To decommission the control valve for service
and repair work or disassembly, proceed as
follows:

1. Close the shut-off valves upstream and

downstream of the control valve to stop

the process medium from owing

through the valve.

2. Completely drain the pipelines and

valve.

3. Disconnect and lock the pneumatic air
supply to depressurize the actuator.

4. If necessary, allow the pipeline and valve
components to cool down or heat up.

9.2 Removing the valve from

the pipeline

1. Put the control valve out of operation (see
section9.1).

2. Cut the pipeline in front of the weld

seam.

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

Î Observe local, national, and internation-

al refuse regulations.

DANGER

!

WARNING

!

WARNING

!

EB 8093 EN 51

Decommissioning and disassembly

Î Do not dispose of components, lubri-

cants, and hazardous substances togeth­er with your other household waste.

52 EB 8093 EN

Appendix

10 Appendix

10.1 After-sales service

Contact SAMSON's After-sales Service de­partment for support concerning service or
repair work or when malfunctions or defects
arise.

E-mail

You can reach the After-sales Service De­partment at [e-mail].

Addresses of SAMSONAG and its subsid­iaries

The addresses of SAMSON AG, its subsid­iaries, 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 Operat­ing Instructions.

Required specications

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)

− Is a strainer installed?

− Installation drawing

10.2 Certicates

The declaration of conformity is provided on
the next page.

EB 8093 EN 53

SAMSON AKTIENGESELLSCHAFT
Weismüllerstraße 3 60314 Frankfurt a m Main

Telefon: [phone] · Telefax: 069 400 9-1507
E-Mail: samson@sam son.de

Revison 01

ce_modul_h_de_en_rev01.d ocx

Modul/Module H / N° CE-PED-H-SAM 001-13-DEU

SAMSON erklärt in alleiniger Verantwortung für folgende Produkte/explaines in sole resposibility for the following products:

Geräte/Devices

Bauart/Series

Typ/ Type

Ausführung/Version

Durchgangsventil/Gl obe Valve 240 3241

DIN, Gehäuse GG/Ca st iron-Body ab/fr om DN150, Gehäuse GGG /Sph. gr.

iron-Body ab/from DN 100, Fluide/Fluids G 2, L1, L2

1)

DIN/ANSI, Geh. Stahl u.a./B ody Steel etc., alle Fluide/ all Fluids

Dreiwegeventil/Three -way Valve 240 3244

DIN, Gehäuse GG ab DN 150/Cast iron-Bod y from DN150; Gehäuse GG G ab

DN100/Sph. gr. iron-B ody from DN100, Fl uide/Fluids G2, L1, L2

1)

DIN/ANSI, Geh. Stahl u.a./B ody Steel etc., alle Fluide/ all Fluids

Tieftemperaturventi l/Cryogenic Valve 240 3248 DIN/ANSI, alle Fluide/all Fluids

Durchgangsventil/Gl obe Valve 250 3251 DIN/ANSI, alle Fluide/all Fluids

Dreiwegeventil/Three -way Valve 250 3253 DIN/ANS I, Geh. Stahl u.a./Bod y Steel etc., alle Fluide/ all Fluids

Durchgangsventil/Gl obe Valve 250 3254 DIN/ANSI, alle Fluide/all Fluids

Eckventil/Angle Valve 250 3256 DIN/ANSI, alle Fluide/all Fluids

Split-Body-Ventil/S plit-Body-Valve 250 3258 DIN, alle Fluide/all Fluids

IG-Eckventil/IG-Angl e Valve 250 3259 DIN, alle Fluide/all Fluids

Dampfumformventil/

Steam-converting Val ve

280

3281 DIN/ANSI, alle Fluide/all Fluids
3284 DIN/ANSI, alle Fluide/all Fluids
3286 DIN/ANSI, alle Fluide/all Fluids
3288 D IN, alle Fluide/all Fl uids

Durchgangsventile/G lobe Valve V200 1 3321

DIN, Geh. Stahl u.a./B ody Steel etc., all e Fluide/all Fluids

ANSI, alle Fluide/all Fluids

Dreiwegeventil/Three -way Valve V2001 3323

DIN, Geh. Stahl u.a./B ody Steel etc., all e Fluide/all Fluids

ANSI, alle Fluide/all Fluids

Schrägsitzventil/Bev el-Valve --- 3353 DIN, Geh. S tahl/Body Steel, all e Fluide/all Fluids

Drosselschalldämpfe r/Silencer 3381

3381-1

DIN/ANSI, alle Fluide/all Fluids; Einzeldrosselscheibe mit Anschweißende/

Single attenuation plate wit h welding end

3381-3 DIN/ANSI, alle Fluide/all Flui ds

3381-4

DIN/ANSI, alle Fluide/all Fluids; Einzeldrosselscheibe mehrstufig mit

Anschweißende/Single attenuation plat e multi-stage with weldi ng end

Durchgangsventil/Gl obe Valve 240 3241

ANSI, Gehäuse GG Cl 125 ab 5"/Cast iron-B ody Cl125 from 5", Fluide/Fluids

G2, L1, L2

1)

Tieftemperaturventi l/

Cryogenic Valve

240 3246 DIN /ANSI, alle Fluide/all Fluid s

Dreiwegeventil/Three -way Valve 250 3253

DIN, Gehäuse GG ab DN 200 PN16/Cast iron-B ody from DN200 PN 16,

Fluide/Fluids G2, L1, L2

1)

Durchgangsventil/Gl obe Valve 290 3291 ANSI, alle Fluide/all Flui ds

Eckventil/Angle Val ve 290 3296 ANSI, alle Fl uide/all Fluids

Durchgangsventil/Gl obe Valve 590 3591 ANSI, alle Fluide/all Flui ds

Eckventil/Angle Val ve 590 3596 ANSI, alle Fl uide/all Fluids

1)

Gase nach Art. 4 Abs.1 Pkt. c.i zweiter Gedankenstrich//Gases acc. to Article 4, Section 1 Subsection c.i second indent

Flüssigkeiten nach Art. 4 Abs.1 Pkt. c.ii//Liquids acc. to Article 4, Section 1 Subsection c.ii

die Konformität mit nachfolgender Anforderung/we declare conformity with the demands of the:

Richtlinie des Europäischen Parla

ments und des Rates zur Harmonisierung der

Rechtsvorschriften der Mitgliedstaaten über die Bereitstellung von Druckgeräten auf dem
Markt/Directive of the European Parliament and oft the Council on the harmonisation of the
laws of the Member States relating to the making available on the market of pressure
equipmentSiehe auch Artikel 41 und 48/See also Article 41 and 48

2014/68/EU

vom/of

15.05.2014

Angewandtes Konformitätsbewertungsverfahren/

Applied Conformity Assessment Procedure

für Fluide nach Art. 4 Abs. 1/for fluids acc. to Article 4, Section 1

Modul H/

Module H

durch/by

Bureau Veritas

0062

Das Qualitätssicherungssystem des Herstellers wird von folgender benannten Stelle überwacht/The Manufacturer’s

Quality Assurance System is monitored by following Notified Body:

Bureau Veritas S. A. nr 0062 67/71, boulevard du Château, 92200 Neuilly-sur-Seine, France

Angewandte technische Spezifikation/Technical Standards used: DIN EN12516-2; DIN EN12516-3; ASME B16.34

Hersteller/Manufacturer: SAMSON AG, Weismüllerstraße 3, 60314 Frankfurt

Frankfurt, 19.07.2016

Klaus Hörschken
Zentralabteilungsleiter / Head of Central Department
Entwicklung Ventile und Antriebe / R&D Valves and Actuators

Günther Scherer
Zentralabteilungsleiter / Head of Central Department
Qualitätsmanagement / Total Quality Management

54 EB 8093 EN

EB 8093 EN 55

Appendix

10.3 Spare parts

1 Body
2 Valve bonnet
3 Yoke

4 Seat

5 Plug (with plug stem)
7 Guide bushing

8 Threaded bushing (packing nut)

9 Stem connector nut

10 Lock nut

11 Spring

12 Washer

13 Stud bolt

14 Body nuts

15 Packing

16 V-ring packing

17 Bonnet gasket

22 Bellows seal

24 Guide bushing

27 Flange

28 Clamping ring

30 Retaining washer

31 Washer

32 Hexagon bolt

33 Nut

35 Lock nut

37 Plug stem with metal bellows

42 Screw plug (test connection)

43 Seal

57 Flange

58 Flange

71 Spacer stem

77 Plate (direction of ow)

80 Nameplate

81 Grooved pin

82 Fillister head screw

83 Hanger

84 Travel indicator scale

92 Castellated nut

119 Support nut

56 EB 8093 EN

PN63…100

PN16…40

32

17

9

10

8

12

33

2

11

3

80

92

83

82

17

33

2

32

15

81

84

84

16

7

80

81

83

82

PN16…40

EB 8093 EN 57

24

5

28

27

31

35
34

1

42

37

35

24

35

5

71

41

4

77
81

5

35

119

24

35

30

43

37

PN63…100

PN16…40

Globe valve with stainless steel body

58 EB 8093 EN

DN 15…150/PN 16…40

DN 25…100/PN 16…40

9

10
8

9

10

8

12
11

84

83

82

3

33

2

17

32

92

81

80

7

84

83

82

2

80

81

11

32

16

16

15

12

15

33

EB 8093 EN 59

1

39

13

14

22

71

41

37

4

80

77

35

24

5

30

35

57

58

Angle valve with aluminum body

SAMSON AG · MESS- UND REGELTECHNIK
Weismüllerstraße 3 · 60314 Frankfurt am Main, Germany
Phone: [phone] · Fax: [phone]
[e-mail] · www.samson.de

EB 8093 EN

2017-06-28 · English