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 Type3271 or Type3277 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 (aftersalesservice@samson.de).
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.
Denition 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, PN16 to 40 ...............................................................43
7.1.2 Globe or angle valve, PN63 and 100...........................................................44
7.2 Replacing the packing ..................................................................................45
7.2.1 Globe or angle valve, PN16 to 40 ...............................................................45
7.2.2 Globe or angle valve, PN63 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 Certicates ..................................................................................................52
10.3 Spare parts .................................................................................................55
EB 8093 EN 5
Safety instructions and measures
1 Safety instructions and measures
Intended use
The SAMSON Type3248 Globe and Angle Valve in combination with an actuator (e.g.
Type3271 or Type3277 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 dened 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 specications used for sizing the valve at the ordering stage. In case
operators intend to use the control valve in other applications or conditions than specied,
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 dened during sizing and in the technical data
− Use outside the limits dened 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
Qualications of operating personnel
The control valve must be mounted, started up, serviced, and repaired by fully trained and
qualied 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 modications
Revisions, conversions or other modications 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 section3.1). The fail-safe action of the actuator is the same as its direction of action and is specied 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 specied 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 section10.2).
According to the ignition risk assessment performed in accordance with EN13463-1:2009,
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 specied in
section 6.4 of EN60079-14 (VDE0165 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. uEB8310-X for
Type3271 and Type3277 Actuators
− Mounting and operating instructions for mounted valve accessories (positioner, solenoid
valve etc.)
− uAB0100 for tools, tightening torques, and lubricant
− For oxygen service: Manual uH01
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 Type3248 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.
Unqualied operating personnel expose themselves and others to an increased risk of
injury.
Î Operating personnel must be sufciently 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 uH01.
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 identied 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 dened properties.
Î Only use the process medium specied for sizing the valve.
Risk of leakage and valve damage due to excessively high or low tightening torques.
Observe the specied 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 specied tightening torques (uAB0100).
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 (uAB0100).
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 (uAB0100).
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 notied 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 modication index
For after-sales service orders: AA prex
13 Position in order
For after-sales service orders: conguration ID
14 Flow coefcient:
DIN: K
VS
· ANSI: C
V
15 Characteristic:
%: equal percentage · Lin: linear
16 Seat-plug seal:
ME: metal (see section3.3)
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 afxed 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 specied on the nameplate
(17 on nameplate). For more details on the
nameplate, see section2.1.
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 Type3248 is available in the following
versions:
− Globe valve with stainless steel body,
DN25 to 150, PN16 to 100 (see Fig.3)
− Angle valve with stainless steel body,
DN25 to 150, PN40 to 100 (see Fig.4)
− Angle valve with aluminum body, DN25
to 150, PN16 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 specic 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 PN16 to 40 version, the valve bonnet
(2) is designed as a yoke (see Fig.3). In the
PN63 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 Type3248 Valve is preferably combined
with a SAMSON Type3271 or Type3277
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 section3.1). A change in the signal
pressure acting on the diaphragm causes the
EB 8093 EN 15
Design and principle of operation
Fig.3: Type3248 Globe Valve with
stainless steel body (PN16 to 40)
and with Type3271 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: Type3248 Angle Valve with stainless steel
body (PN100)
Fig.5: Type3248 Angle Valve with aluminum
body (PN16 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:
uEB8310‑X for Type3271 and Type3277
3.2 Versions
Larger nominal sizes
The Type3248 Valve is available up to nominal size DN200.
Actuators
In these instructions, the preferable combination with a Type3271 or Type3277 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 section2.1 and the actuator
documentation.
More information is available in Data Sheet
uT8093.
Compliance
The Type3248 Valve bears both the CE and
EAC marks of conformity.
Temperature range
The Type3248 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 IEC60534-4
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
IEC60534, Part8-3 and Part8-4 or
VDMA24422 (edition 89).
Risk of hearing loss or deafness due to loud
noise.
Wear hearing protection when working near
the valve.
Dimensions and weights
Table1 to Table5 provide a summary of the
dimensions of the various versions of
Type3248 Valve. Table6 lists the weights of
the various versions of Type3248 Valve. The
lengths and heights in the dimension dia-
grams are shown on page22.
Note
Note
WARNING
!
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