Samson 3286 Mounting And Operating Instructions

Download

Page 1

Type3286 Steam Conditioning Valve

In combination with an actuator,

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

ANSI version

Translation of original instructions

Mounting and Operating Instructions

EB 8257 EN

Edition March 2017

Page 2

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.

Denition of signal words

DANGER

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

WARNING

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

2 EB 8257 EN

NOTICE

Property damage message or malfunction

Note

Additional information

Tip

Recommended action

Page 3

Contents

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

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

1.2 Notes on possible personal injury ...................................................................8

1.3 Notes on possible property damage ................................................................9

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 ........................................................................................14

3.2 Versions ......................................................................................................16

3.3 Technical data .............................................................................................16

4 Measures for preparation ............................................................................20

4.1 Unpacking ..................................................................................................20

4.2 Transporting and lifting ................................................................................20

4.2.1 Transporting ................................................................................................21

4.2.2 Lifting ..........................................................................................................21

4.3 Storage .......................................................................................................24

4.4 Preparation for installation ............................................................................25

5 Mounting and start-up .................................................................................26

5.1 Mounting the actuator onto the valve .............................................................26

5.2 Installing the valve into the pipeline ...............................................................27

5.2.1 Checking the installation conditions ...............................................................27

5.2.2 Additional ttings .........................................................................................28

5.2.3 Installing the control valve .............................................................................29

5.3 Putting the control valve into operation...........................................................30

5.4 Quick check ................................................................................................30

6 Operation ...................................................................................................32

6.1 Working in manual mode .............................................................................32

7 Servicing.....................................................................................................34

7.1 Preparing the valve for servicing ...................................................................35

EB 8257 EN 3

Page 4

Contents

7.2 Replacing gaskets ........................................................................................35

7.3 Replacing the packing ..................................................................................38

7.4 Replacing the seat and plug ..........................................................................40

7.5 Determining the number of shims required .....................................................42

7.6 Completion of servicing activities ...................................................................42

7.7 Preparation for return shipment .....................................................................44

7.8 Ordering spare parts and operating supplies .................................................44

8 Malfunctions ...............................................................................................46

8.1 Troubleshooting ...........................................................................................46

8.2 Emergency action ........................................................................................47

9 Decommissioning and disassembly ..............................................................48

9.1 Decommissioning .........................................................................................48

9.2 Removing the valve from the pipeline .............................................................48

9.3 Removing the actuator from the valve ............................................................49

9.4 Disposal ......................................................................................................49

10 Annex.........................................................................................................50

10.1 After-sales service ........................................................................................50

10.2 Certicates ..................................................................................................50

10.3 Spare parts .................................................................................................53

4 EB 8257 EN

Page 5

Safety instructions and measures

1 Safety instructions and measures

Intended use

The SAMSON Type3286 Steam Conditioning Valve in combination with an actuator (e.g. Type3271 or Type3277 Pneumatic Actuator) is designed to regulate the pressure and

temperature of steam. The valve is intended for use in for process engineering applications

and thermal plants. 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 applications 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, contact SAMSON.

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.

EB 8257 EN 5

Page 6

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 hot, cold, 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. Furthermore, the product may no longer meet the requirements for its intended use.

Safety devices

Upon supply air or control signal failure, the valve moves to its fail-safe position (see 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 operating 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 applicable health, safety and accident prevention regulations and comply with them.

6 EB 8257 EN

Page 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

SAMSON 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

EB 8257 EN 7

Page 8

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.

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.

8 EB 8257 EN

Page 9

Safety instructions and measures

WARNING

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. (chemical) 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.

Risk of burn injuries due to hot or cold components and pipelines.

Depending on the process medium, valve components, and pipelines may get very hot

or cold and cause burn injuries.

Î Allow components and pipelines to cool down or 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 Pickle and blow through the steam pipe. Î Observe the maximum permissible pressure for valve and plant.

EB 8257 EN 9

Page 10

Safety instructions and measures

NOTICE

Risk of valve damage due to unsuitable medium properties.

The valve is designed for steam and cooling water.

Î Make sure that the steam and cooling water are clean and free of mineral

components.

Î Install strainers.

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).

10 EB 8257 EN

Page 11

EB 8257 EN 11

Page 12

Markings on the control valve

2 Markings on the control valve

2.1 Valve nameplate

SAMSON

1…5

6 8 10 11 12 13

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:

· ANSI: C

DIN: K

15 Characteristic:

%: equal percentage · Lin: linear

16 Seat-plug seal:

ME: metal (see section3.3)

HA: carbide metal ST: Stellite

facing

17 Seat code (trim material) · On request 18 Pressure balancing:

DIN: D · ANSI: B

19 Flow divider:

3: ST3

20 Country of origin

12 EB 8257 EN

Page 13

The nameplate (80) is afxed to the yoke of

the valve (see Fig.2).

Fig.2: Location of the nameplate

2.2 Actuator nameplate

Markings on the control valve

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.

EB 8257 EN 13

Page 14

Design and principle of operation

3 Design and principle of oper-

ation

The single-seated Type3286 Angle Valve acts as a steam conditioner and is tted with a ow divider ST3. The Type3286 Steam Conditioning Valve is preferably combined with a SAMSON Type3271 or Type3277 Pneumatic Actuator (see Fig.3). It can also

combined with other actuators.

The seat (4), ow divider (62), and plug with plug stem (5) are installed in the body (1).

The plug stem is connected to the actuator

stem (A7) by the stem connector clamps (A26/27) and is sealed by a spring-loaded V-ring packing (15). Alternatively, an adjust-

able high-temperature packing can be used. The springs in the pneumatic actuator are

located either above or below the

diaphragm (A4) depending on the selected fail-safe action (see section3.1). A change

in the signal pressure acting on the diaphragm causes the plug to move. The actuator size is determined by the diaphragm area.

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 and the pressure p

as well.

The cooling water is fed to the ow divider (62) through the connecting pipe on the bon-

net (2) and holes in the clamping element (63). After owing through the cross-section-

al area between seat and plug, the steam

ow reaches its maximum velocity and

comes into contact with the cooling water at

the inner wall of the ow divider. The steam ow and the entrained water are mixed in the narrow wire mesh of the ow divider. At

the same time, the steam velocity is reduced, releasing some of its heat to the water across the large surface of the wire mesh coil, which causes it to evaporate quickly. The

steam/water mixture leaves the ow divider as a ne mist with a high steam content. Evaporation is completed a short distance

downstream of the steam conditioning valve. The water atomization described is ensured over the whole load range since the steam velocity at the throttling point is independent

of the ow rate.

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.

14 EB 8257 EN

Page 15

A10

A26/27

A8 A7

Water

Design and principle of operation

9 10 8 92

3 15 2

14 17 7

63 5 62

Throttled and cooled steam

4 1

Superheated

1 Body 2 Bonnet (with connecting pipe) 3 Yoke 4 Seat 5 Plug (with plug stem) 7 Guide bushing

8 Threaded bushing (packing nut) 9 Stem connector nut

10 Lock nut 14 Body nut 15 Packing

steam

p3t

17 Body gasket 62 Flow divider ST3 63 Clamping element 84 Travel indicator scale 92 Castellated nut A4 Diaphragm A7 Actuator stem A8 Ring nut

A10 Spring

A26/27

Stem connector clamps

S Signal pressure connection

Fig.3: Type3286 Valve with Type3271 Pneumatic Actuator

EB 8257 EN 15

Page 16

Design and principle of operation

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.

Tip

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

The modular design allows an insulating section or metal bellows to be tted to the standard valve version.

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.

Note

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 or by an electric actuator.

3.3 Technical data

The nameplates on the valve and actuator provide information on the control valve version. See section2.1 and the associated actuator documentation.

Note

More information is available in Data Sheet

uT8257.

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).

WARNING

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

16 EB 8257 EN

Page 17

Design and principle of operation

Table1: Technical data for Type3286

Material Cast steel · A216 WCC Cast steel · A217 WC6 Valve size NPS 2 to 12

Pressure rating Class 150 to 900

Type of connection

Seat-plug seal Metal seal or high-performance metal seal

Characteristic Equal percentage or linear Rangeability 50:1

Compliance

Temperature ranges · Permissible operating pressures acc. to pressure-temperature diagrams (see Information Sheet uT8000-2)

Body without insulating section

Body with Insulating section

Valve

plug

Leakage class according to ANSI/FCI70-2

Valve

plug

Standard Metal seal –20 to +932°F (–29 to 500°C)

Balanced with PTFE –20 to +428°F (–29 to +220°C) Balanced with graphite ring –20 to +932°F (–29 to +500°C)

Standard

Balanced with PTFE Standard: IV · High-performance metal seal: V Balanced with graphite ring IV

Flanges ASMEB16.5 Welding ends ASMEB16.25

14 to 428°F (–10 to +220°C) · Up to 660°F (up to

350°C) with high-temperature packing

–20 to +800°F (–29 to

+427°C)

Metal seal IV High-performance

metal seal

–20 to +932°F (–29 to

+500°C)

Dimensions and weights

Table2 and Table3 provide a summary of the dimensions and weights of the standard version of Type3286 Valve. The lengths and heights in the dimensional drawing are shown on p.18.

Dimensions in mm · Weights in kg

EB 8257 EN 17

Page 18

Design and principle of operation

Dimensional drawing

Note

The dimensions H6 and L3 for the cooling water connection are available on request.

Refer to the following data sheets for more dimensions and weights:

uT8257 for valves with bellows seal or

insulating section

The associated actuator documentation applies to actuators, e.g. for 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

Type3286 Valve with anges

1000cm² actuator area and larger

uT8310‑3 for Type3271 Actuator with

1400‑60cm² actuator area

Table2: Dimensions for Type3286 Valve · Face‑to face dimensions according to ANSI/ISA‑

75.08.01 for Class600 and lower and according to ASME B16.10 for Class900 and higher

Valve

Class150

Class 300

Length L2

Class 600

Class 900

Class 150 to

Height

Class 900

NPS 2 3 4 6 8 10 12

DN 50 80 100 150 200 250 300

in 5.00 5.88 6.94 8.88 10.69

mm 127 149 176 226 272

in 5.25 6.25 7.25 9.31 11.19

mm 133 159 184 236 284

in 5.62 6.62 7.75 10.00 12.00

mm 143 168 197 254 305

in 7.25 7.50 9.00 12.00 14.50

mm 184 190 229 305 368

in 6.89 6.30 6.69 9.13

600

mm 175 160 170 210

in 8.70 6.30 6.69 9.13

mm 221 160 170 210

On request

18 EB 8257 EN

Page 19

Design and principle of operation

Valve

350cm²

355cm²

700cm²

NPS 2 3 4 6 8 10 12

DN 50 80 100 150 200 250 300

in 9.45 9.45 9.45

mm 240 240 240

9.45 9.45 9.45 16.46

240 240 240 418

9.45 9.45 9.45 16.46 16.46

mm 240 240 240 418 418

750cm²

H8 for actuator

1000cm²

1400-60cm²

1400-120cm²

2800cm²

2x2800cm²

H8 = 25.60" (650 mm) with 9.84" (250 mm) seat bore

9.45 9.45 9.45 16.46 16.46 16.46

mm 240 240 240 418 418 418

in 11.61 11.61 11.61 16.46 16.46

mm 295 295 295 418 418

in 11.61 11.61 11.61 16.46 16.46 19.81 19.81

mm 295 295 295 418 418 503 503

in 18.90 18.90 18.90 19.81 19.81 19.81 19.81

mm 480 480 480 503 503 503 503

in 18.90 18.90 18.90 19.81 19.81 25.60 25.60

mm 480 480 480 503 503 650 650

in 18.90 18.90 18.90 19.81 19.81 19.81

mm 480 480 480 503 503 503

–

1)

25.60

1)

650

Table3: Weights for Type3286

Valve

without actuator

Class150

Class 300

Class 600

Class 900

NPS 2 3 4 6 8 10 12

DN 50 80 100 150 200 250 300

lbs 66 110 152 342 948 1892 2028

kg 30 50 69 155 460 858 920

lbs 95 170 247 694 948 1892 2028

kg 43 77 112 315 430 858 920

lbs 95 170 247 694 1096 2509 2535

kg 43 77 112 315 497 1138 1150

lbs 95 170 247 694 1157 2844 3263

kg 43 77 112 315 525 1290 1480

EB 8257 EN 19

Page 20

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

Note

Do not remove the packaging until immediately before installing the valve into the pipeline.

Proceed as follows to lift and install the

valve:

1. Remove the packaging from the valve.

2. Dispose of the packaging in accordance

with the valid regulations.

4.2 Transporting and lifting

DANGER

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

WARNING

Risk of lifting equipment tipping and risk of damage to lifting accessories due to exceeding the rated lifting 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 or Data Sheet

uT8257 for weights.

WARNING

Risk of personal injury due to control valve tipping.

− Observe the valve's center of gravity.

− Secure the valve against tipping over or

turning.

NOTICE

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.

20 EB 8257 EN

Page 21

Measures for preparation

NOTICE

Risk of valve damage due to incorrectly attached slings. The lifting eyelet/eyebolt 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/eyebolt 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 cooling water connection.

− Observe lifting instructions (see sec- tion4.2.2).

Tip

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 (–4 to +149°F).

Note

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

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.

EB 8257 EN 21

Page 22

Measures for preparation

− Prevent the control valve from tilting or tipping.

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

− Make sure that the axis of the pipeline is always horizontal during lifting and the axis of the plug stem is always vertical.

− Make sure that the additional sling be- tween the lifting eyelet/eyebolt and rigging equipment (hook, shackle etc.) does not bear any load when lifting valves larger than NPS6. The sling only protects the control valve from tilting while

being lifted. Before lifting the control

valve, tighten the sling.

− Make sure that the cooling water connec- tion on the bonnet is not bent by the slings.

Fig.4: Lifting points on the control valve: with anges (left) and with welding ends (right)

22 EB 8257 EN

Page 23

Measures for preparation

Version with anges

1. Attach one sling to each ange of the

body and to the rigging equipment (e.g.

hook) of the crane or forklift (see Fig.4).

2. NPS6 and larger: Attach another sling to the lifting eyelet/eyebolt on the actua-

tor and to the rigging equipment.

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5.2).

6. After installation in the pipeline, check whether the anges are bolted tight and

the valve in the pipeline holds.

7. Remove slings.

Version with welding ends

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.4).

2. Secure the slings attached to the body

against slipping using a connector.

3. NPS6 and larger: Attach another sling to the lifting eyelet/eyebolt on the actua-

tor 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5.2).

7. After installation in the pipeline, check

whether the weld seams hold.

8. Remove slings.

Tip

We recommend using a hook with safety latch (see Fig.4). The safety latch prevents the slings from slipping during lifting and transporting.

EB 8257 EN 23

Page 24

Measures for preparation

4.3 Storage

NOTICE

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.

Note

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 (–4 to +149°F).

Note

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 (59°F) for elastomers.

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

Tip

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

24 EB 8257 EN

Page 25

4.4 Preparation for installation

Proceed as follows:

Î Flush the pipelines.

Note

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

Î Pickle and blow through the steam pipe. 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 Make sure that the pipelines are dry.

Moisture will damage the inside of the valve.

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.

Measures for preparation

EB 8257 EN 25

Page 26

Mounting and start-up

5 Mounting and start-up

SAMSON valves are delivered ready for use. In special cases, the valve and actuator are delivered separately and must be assembled on site. The procedure to mount and start up the valve are described in the following.

NOTICE

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

NOTICE

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

5.1 Mounting the actuator onto the valve

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

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.

Tip

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.

NOTICE

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.

Note

− Remove the mounted actuator before mounting the other actuator (see associated 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).

26 EB 8257 EN

Page 27

Mounting and start-up

5.2 Installing the valve into the pipeline

5.2.1 Checking the installation

conditions

Pipeline routing

To ensure the control valve functions properly, follow the installation instructions given below:

Î To determine the required inlet and outlet

lengths as well as how the pipeline is to be routed, contact SAMSON.

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.

Tip

Fig.5 shows a sample assembly of a steam pressure/temperature control with steam conditioner.

Mounting position

The control valve must always be installed with the actuator upright on top.

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

Premature wear and leakage due to insufcient support or suspension. Attach a suitable support or suspension to the valve.

Water

Superheated

steam

1 Transmitter 2 Controller

Fig.5: Steam pressure/temperature control with steam conditioner

3 Steam conditioner 4 Control valve for cooling water

Throttled and cooled steam

EB 8257 EN 27

Page 28

Mounting and start-up

Flanges

− The anges of the cooling water valve as well as the inlet and outlet anges of the

steam conditioning valve must be designed for the same pressure rating.

− To facilitate the separation of the steam conditioning valve and cooling water valve for repair and servicing work, a ange must be used to connect the cooling water valve to the steam conditioning

valve. If necessary, t a blind ange.

Temperature sensor

Î Install a temperature sensor at least 10m

downstream of the valve.

Note

The exact distance is determined at the valve sizing stage based on the operating data.

Vent plugs

Vent plugs are screwed into the exhaust air

ports of pneumatic and electropneumatic 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.

Note

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

5.2.2 Additional ttings

Steam trap

Automatic steam traps must be installed at the lowest point in the upstream and downstream lines to ensure proper functioning of the plant.

Check valve

We recommend installing check valves between the steam conditioning valve and the cooling water valve to protect the condensate system.

Strainers

It prevents solid particles in the process medium from damaging the valve. We recommend installing a strainer upstream of the valve body and in the inlet pipe for water supply.

Bypass and shut-off valves

We recommend installing a shut-off valve

both upstream of the strainer and downstream of the valve and installing a bypass line. The bypass ensures that the plant does not need to be shut down for service and repair work on the valve.

28 EB 8257 EN

Page 29

Mounting and start-up

Insulation

Only insulate control valves with insulating section or bellows seal up to the bonnet

ange of the valve body for medium temperatures below 0°C (32°F) and above 220°C (428°F).

Test connection

Versions with bellows seal tted with a test

connection (G

) on the top bonnet allow the sealing ability of the bellows to be monitored.

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).

WARNING

Risk of personal injury due to pressurized components and process medium escaping under pressure. Do not loosen the screw of the test connection while the valve is in operation.

Safety guard

To reduce the crush hazard arising from moving parts (actuator and plug stem), a safety guard can be installed.

Noise emission

A further noise reduction can only be achieved by using additional insulation as the steam conditioning valve is already

equipped with ow divider ST3.

Valve accessories

If excessive heat is radiated by the steam conditioning valve, only mount valve accessories (e.g. positioners) on the inlet side of the cooling water valve.

5.2.3 Installing the control valve

Version with anges

1. Close the shut-off valve in the pipeline

while the valve is being installed.

2. Remove the protective caps from the

valve ports before installing the valve.

3. Lift the valve using suitable lifting equip-

ment to the site of installation (see sec-

tion4.2.2). Observe the ow direction

through the valve. The arrow on the

valve indicates the direction of ow.

4. Make sure that the correct ange gaskets

are used.

5. Bolt the pipe to the valve free of stress.

6. Connect the cooling water pipeline and

cooling water valve.

Version with welding ends

1. Proceed as described for Version with

anges (steps 1 to 3).

2. Completely retract the actuator stem to

protect the plug from sparks during welding.

3. Weld the valve free of stress into the

pipeline.

4. Connect the cooling water pipeline and

cooling water valve.

EB 8257 EN 29

Page 30

Mounting and start-up

5.3 Putting the control valve into operation

1. Depending on the eld of application,

allow the valve to cool down or heat up to reach ambient temperature before start up.

2. Set the controller (2) to 'manual' to en-

sure that the plant can slowly warm up by slightly opening the steam conditioner.

3. Set the controller (3) for the water supply

to 'automatic' to ensure it can react quickly to changes at the temperature sensor of the transmitter.

4. Slowly open the shut-off valve in the

pipeline after the valve has been installed.

NOTICE

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.

5. Check the valve to ensure it functions

properly.

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:

Leakage

1. Close the valve.

2. Slowly open the shut-off valve in the

pipeline.

NOTICE

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.

30 EB 8257 EN

Page 31

Mounting and start-up

Fail-safe position

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

fail-safe position.

Adjustable packing

Tip

A label on the yoke (3) indicates whether an adjustable packing is installed.

1. Tighten the threaded bushing gradually (by turning it clockwise) until the packing seals the valve.

NOTICE

Risk of valve damage due to the threaded bushing tightened too far. Make sure that the plug stem can still move smoothly after the threaded bushing has been tightened.

2. Open and close the valve several times.

3. Check the valve for leakage (visual in-

spection).

4. Repeat steps 1 and 2 until the packing

completely seals the valve.

− Retract the plug stem to open the valve.

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

Note

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

If the adjustable packing does not seal properly, contact SAMSON's After‑sales Service department.

Pressure test

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

EB 8257 EN 31

Page 32

Operation

6 Operation

Immediately after completing mounting and

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

use.

WARNING

Crush hazard arising from moving parts (actuator and plug stem). Do not insert hands or ngers into the yoke while the valve is in operation.

WARNING

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

WARNING

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

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.

NOTICE

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.

32 EB 8257 EN

Page 33

EB 8257 EN 33

Page 34

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.

Tip

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

DANGER

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.

WARNING

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.

WARNING

Risk of burn injuries due to hot or cold components and pipeline. Valve components and the pipeline may become very hot or cold. Risk of burn injuries.

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

− Wear protective clothing and safety gloves.

NOTICE

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

NOTICE

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

34 EB 8257 EN

Page 35

Servicing

NOTICE

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

Note

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 service 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.

7.2 Replacing gaskets

NOTICE

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

− The valve size is ≤NPS6.

− The valve does not have a balanced plug.

− The valve does not have a bellows seal.

− The valve does not have an insulating sec-

tion. To replace the gaskets in other valve versions, contact SAMSON's After‑sales Service department.

The following gaskets are installed and must be exchanged:

− Body gasket (17)

− Shims 0.5mm (64)

− Shims 2mm (65)

− Graphite ber packing (67)

7.1 Preparing the valve for servicing

1. Put the control valve out of operation (see

section9.1).

2. Undo the ange joint between the cool-

ing water valve and steam conditioning valve.

3. Remove the steam conditioning valve

from the pipeline (see section9.2).

EB 8257 EN 35

Note

Measure how many shims (64, 65) are required (see section7.5).

1. Remove the actuator from the valve. See

associated actuator documentation.

2. Undo the body nuts (14) gradually in a

crisscross pattern.

3. Lift the bonnet (2), yoke (3), and plug with plug stem (5) off the body (1).

4. Remove the gaskets (17, 64, 65) and graphite ber packing (67). Carefully

Page 36

Servicing

A10

A26/27

A8 A7

9 10 8 92

3 15 2

14 17 7

63 5 62

4 1

1 Body 2 Bonnet (with connecting pipe) 3 Yo ke 4 Seat 5 Plug (with plug stem) 7 Guide bushing

8 Threaded bushing (packing nut) 9 Stem connector nut

10 Lock nut 14 Body nut 15 Packing

p3t

17 Body gasket 62 Flow divider ST3 63 Clamping element 84 Travel indicator scale 92 Castellated nut A4 Diaphragm A7 Actuator stem A8 Ring nut

A10 Spring

A26/27 Stem connector clamps

S Signal pressure connection

Fig.6: Type3286 with Type3271 Actuator

36 EB 8257 EN

Page 37

Servicing

17 64

clean the sealing faces in the valve body

(1), on the bonnet (2) and clamping element (63).

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

6. Place the new graphite ber packing (67) on the clamping element (63).

7. Place the new shims (64, 65) on the graphite ber packing. For this purpose,

measure how many shims are required

as described in section7.5.

8. Make sure that the ow divider (62) is still clamped correctly on the seat (4).

9. Place the bonnet (2) together with the plug stem and plug (5) onto the body.

Version with V-port plug: place the bon-

net (2) onto the valve body, making sure that the largest V-shaped port of the V-port plug faces toward the valve outlet. See section5.1.

10. Firmly press the plug (5) into the seat (4). Fasten down the bonnet (2) with the body nuts (14). Tighten the nuts gradual-

ly in a crisscross pattern. Observe tightening torques.

11. Mount actuator. See associated actuator documentation.

12. Adjust lower or upper signal bench

range. See associated actuator documentation.

2 Bonnet 17 Body gasket 62 Flow divider 63 Clamping element 64 Shim 65 Shim 67 Graphite ber

packing

Fig.7: Gaskets

EB 8257 EN 37

Page 38

Servicing

7.3 Replacing the packing

NOTICE

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

− The valve size is ≤NPS6.

− The valve does not have a balanced plug.

− The valve does not have a bellows seal.

− The valve does not have an insulating sec-

tion.

− The standard packing, FormH or FormHT packing is installed in the valve.

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

NOTICE

Damage to the packing (FormH, FormHT) by the use of lubricant. The FormH and FormHT packings contain graphite. Do not use any lubricant during the installation of these packings.

Note

The number of spacers (19) varies depending on the nominal valve size.

Standard and Form H packings

1. Remove the actuator from the valve. See

associated actuator documentation.

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

3. Undo the body nuts (14) gradually in a

crisscross pattern.

4. Lift the bonnet (2) and plug with plug stem (5) off the body (1).

5. Replace the gaskets as described in section7.2.

6. Unthread the stem connector nut (9) and lock nut (10) from the plug stem.

7. Unscrew the threaded bushing (8).

8. Pull the plug with plug stem (5) out of the bonnet (2).

9. Pull all the packing parts out of the packing chamber using a suitable tool.

10. Renew damaged parts. Clean the packing chamber thoroughly.

11. Standard packing: apply a suitable lu- bricant to all the packing parts and to

the plug stem (5).

Form H packing: do not use any lubricant.

12. Slide the plug with plug stem (5) into the bonnet (2).

13. Make sure that the ow divider (62) is still clamped correctly on the seat (4).

14. Place the bonnet (2) together with the plug stem and plug (5) onto the body.

Version with V-port plug: place the bon-

net (2) onto the valve body, making sure that the largest V-shaped port of the V-port plug faces toward the valve outlet. See section5.1.

15. Carefully slide the packing parts over the

plug stem into the packing chamber using a suitable tool. Observe the proper

sequence (see Fig.8).

38 EB 8257 EN

Page 39

Servicing

16. Firmly press the plug (5) into the seat (4). Fasten down the bonnet (2) with the body nuts (14). Tighten the nuts gradual-

ly in a crisscross pattern. Observe tightening torques.

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

18. Place yoke (3) on the bonnet (2) and fasten tight using the castellated nut (92).

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

connector nut (9) onto the plug stem.

20. Mount actuator. See associated actuator documentation.

21. Adjust lower or upper signal bench

range. See associated actuator documentation.

Form HT packing

1. Proceed as described in Standard and Form H packings, steps1 to 16. Do not

use any lubricant.

2. To compress the packing, tighten the packing until reaching the metal stop using a suitable tool.

8 Threaded bushing

11 Spring 12 Washer 16 Packing assembly 18 Spacer 19 Spacer

Fig.8: Packing: standard (left) · FormH (middle) · FormHT (right)

EB 8257 EN 39

Page 40

Servicing

3. Remove tool.

4. Proceed as described in Standard and Form H packings, steps17 to 21.

5. Stroke the plug stem (5) up and down

around ten times to all the packing to settle.

7.4 Replacing the seat and plug

NOTICE

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

− The valve size is ≤NPS6.

− The valve does not have a balanced plug.

− The valve does not have a bellows seal.

− The valve does not have an insulating sec-

tion.

− The standard packing, FormH or FormHT packing is installed in the valve.

To replace seat and plug in other valve versions, contact SAMSON's After‑sales Service department.

NOTICE

Risk of damage to the facing of the seat and plug due to incorrect service or repair. Always replace both the seat and plug.

1. Remove the actuator from the valve. See

associated actuator documentation.

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

3. Undo the body nuts (14) gradually in a

crisscross pattern.

4. Lift the bonnet (2) and plug with plug stem (5) off the body (1).

5. Replace the gaskets as described in section7.2.

40 EB 8257 EN

Page 41

Servicing

6. Unthread the stem connector nut (9) and lock nut (10) from the plug stem.

7. Unscrew the threaded bushing (8).

8. Pull the plug with plug stem (5) out of the bonnet (2).

9. Replace the packing. See section7.3.

10. Make sure that the guide bushing (7) is

not damaged. If necessary, replace the guide bushing using a suitable tool.

11. Remove clamping element (63) and ow divider (62).

12. Unscrew the seat (4) using a suitable

tool.

13. Apply a suitable lubricant to the thread and the sealing cone of the new seat.

14. Screw in the seat (4). Observe tightening

torques.

15. Clamp the ow divider (62) on the seat. Mount the clamping element (63).

16. Slide the new plug with plug stem (5) into the bonnet (2).

17. Place the bonnet (2) together with the plug stem and plug (5) onto the body (1).

Version with V-port plug: place the bon-

net (2) onto the valve body, making sure that the largest V-shaped port of the V-port plug faces toward the valve outlet. See section5.1.

18. Firmly press the plug (5) into the seat (4). Fasten down the bonnet (2) with the body nuts (14). Tighten the nuts gradual-

ly in a crisscross pattern. Observe tightening torques.

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

20. Place yoke (3) on the bonnet (2) and fasten tight using the castellated nut (92).

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

connector nut (9) onto the plug stem.

22. Mount actuator. See associated actuator documentation.

23. Adjust lower or upper signal bench

range. See associated actuator documentation.

EB 8257 EN 41

Page 42

Servicing

7.5 Determining the number of shims required

Determine the number of shims required every time the bonnet (2) is opened. Two different shim sizes are available:

− Shims 0.5mm (64)

− Shims 2mm (65)

After inserting the new gasket (17) as described in section7.2, proceed as follows:

1. Determine dimension A.

2. Determine dimension B.

3. Refer to Table4 for dimensions P and S.

4. Calculate dimension X:

X= (A+ P– B)– 2* S

5. Fill out dimension x with the sufcient

number of shims (64/65) up to ±0.5mm.

6. If dimensionX≥ dimensionS, insert an

additional graphite ber packing (67).

7.6 Completion of servicing activities

Î After completing servicing, put the valve

back into operation (see section5).

Table4: Dimensions for graphite ber packing

Note

The dimensionP is the height of the double‑layered graphite ber packing (67) in the compressed state.

Dimension Up to NPS4 NPS6 to 10 NPS12

S mm 4 8 10

P mm 1.8 3 3.5

42 EB 8257 EN

Page 43

Servicing

17 64

Dim. Explanation

Bottom of the graphite ber packing (67) up to the

top of the gasket (17)

Top of the shim (64/65) up to the top of the gasket

(17)

Height of the double-layered graphite ber packing

(67) (before compression)

X Height of the shims (64/65)

2 Bonnet 17 Body gasket 62 Flow divider 63 Clamping element 64 Shim 65 Shim 67 Graphite ber

packing

Fig.9: Shims at the ow divider

EB 8257 EN 43

Page 44

Servicing

7.7 Preparation for return shipment

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.

7.8 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

See section10.3 for details on spare parts.

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.

44 EB 8257 EN

Page 45

EB 8257 EN 45

Page 46

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.

Tip

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 or plug stem does not move through the whole range.

The valve leaks to the atmosphere (fugitive emissions).

Actuator is blocked. Check attachment.

Unblock the actuator.

Signal pressure too low Check the signal pressure.

Check the signal pressure line for

leakage.

Signal pressure too low Check the signal pressure.

Check the signal pressure line for

leakage.

The packing is defective. Replace packing (see

section7.3) or contact

SAMSON's After-sales Service department.

Version with adjustable

1)

packing correctly.

Version with bellows seal: the

metal bellows seal is defective.

Flange joint loose or gasket

worn out.

: packing not tightened

See section5.4, Adjustable packing. Contact SAMSON's

After-sales Service department when it continues to leak.

Contact SAMSON's After-sales

Service department.

Check the ange joint. Replace gasket at the anged joint (see section7.2 or contact

SAMSON's After-sales Service department).

46 EB 8257 EN

Page 47

Malfunctions

Malfunction Possible reasons Recommended action

Increased ow through closed

valve (seat leakage)

A label on the yoke (3) indicates whether an adjustable packing is installed.

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

Valve trim, particularly with soft

seat, is worn.

Sealing parts, weld spatter, and other impurities carried along by the steam have accumulated.

Shut off the section of the pipe-

line and ush the valve.

Replace seat and plug (see section7.4 or contact

SAMSON's After-sales Service department).

Pickle and blow through the

steam pipe.

Note

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

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

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.

Note

See section5 for further instructions to put back the valve into operation.

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.

EB 8257 EN 47

Page 48

Decommissioning and disassembly

9 Decommissioning and

disassembly

DANGER

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.

WARNING

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.

5. Remove the cooling water pipeline.

9.2 Removing the valve from

the pipeline

Version with anges

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

2. Unbolt the ange joint.

3. Remove the valve from the pipeline (see section4.2).

WARNING

Risk of burn injuries due to hot or cold components and pipeline. Valve components and the pipeline may become very hot or cold. Risk of burn injuries.

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

− Wear protective clothing and safety gloves.

48 EB 8257 EN

Version with welding ends

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

2. Cut the pipeline in front of the weld

seam.

3. Remove the valve from the pipeline (see section4.2).

Page 49

9.3 Removing the actuator from the valve

See associated actuator documentation.

9.4 Disposal

Î Observe local, national, and internation-

al refuse regulations.

Î Do not dispose of components,

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

Decommissioning and disassembly

EB 8257 EN 49

Page 50

Annex

10 Annex

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 aftersalesservice@samson.de.

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 cu.ft/min or m³/h

− Direction of ow

− 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.

50 EB 8257 EN

Page 51

ce_modul_h_de_en_rev03.docx

Modul/Module H / N° CE-0062-PED-H-SAM 001-16-DEU

Geräte/Devices

Bauart/Series

Typ/T ype

Ausführung/Version

Richtlinie des Europäischen Parla

ments und des Rates zur Harmonisierung der

durch/by

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

DIN, Gehäuse GG/Cast iron -Body ab/from DN150, Gehäuse GGG/Sph. gr.

Durchgangsventil/Globe Val ve 240 3241

Dreiwegeventil/Three-way Val ve 240 3244

Tieftemperaturventil/Cryog enic Valve 240 3248 DIN/ANSI, alle Fluide/all Fluids

Durchgangsventil/Globe Val ve 250 3251 DIN/ANSI, alle Fluide/all Fluids

Dreiwegeventil/Three-way Val ve 250 3253 DIN/ANSI, Geh. Sta hl u.a./Body Steel etc., alle Fluide/all Fl uids

Durchgangsventil/Globe Val ve 250 3254 DIN/ANSI, alle Fluide/all Fluids

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

Split-Body-Ventil/Split-B ody-Valve 250 3258 DIN, all e Fluide/all Fluids

IG-Eckventil/IG-Angle Val ve 250 3259 DIN , alle Fluide/all Fluids

Dampfumformventil/

Steam-converting Valve

Durchgangsventile/Globe V alve V2001 3321

Dreiwegeventil/Three-way Val ve V2001 3323

Schrägsitzventil/Bevel-Val ve --- 3353 DIN, Geh. Stahl/Body Steel, alle Fluide/all Fluids

Drosselschalldämpfer/Sile ncer 3381

Durchgangsventil/Globe Val ve 240 3241

Tieftemperaturventil/

Cryogenic Valve

Dreiwegeventil/Three-way Val ve 250 3253

Durchgangsventil/Globe Val ve 290 3291 ANSI, alle Fluide/all Fluids

Eckventil/Angle Valve 290 3296 ANSI, alle Fluide/all Flui ds

Durchgangsventil/Globe Val ve 590 3591 ANSI, alle Fluide/all Fluids

Eckventil/Angle Valve 590 3596 ANSI, alle Fluide/all Flui ds

Regelventil/Control valve --- 3595

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

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

280

240 3246 DIN/ANSI, alle Fluide/all Fluids

3281 DIN/ANSI, alle Fluide/all Fluids 3284 DIN/ANSI, alle Fluide/all Fluids 3286 DIN/ANSI, alle Fluide/all Fluids 3288 DIN, alle Fluid e/all Fluids

3381-1

3381-3 DIN/ANSI, alle Fluide/all Fluids

3381-4

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

Rechtsvorschriften der Mitgliedstaaten über die Bereitstellung von Druckgeräten auf dem Markt/Directive of the European Parliament and oft the Council on the harmonization of the laws of the Member States relating to the making available on the market of pressure equipment

Angewandtes Konformitätsbewertungsverfahren für Fluide nach Art. 4 Abs. 1/ Applied Conformity Assessment Procedure for fluids according to Article 4(1)

Das Qualitätssicherungssystem des Herstellers wird von folgender benannten Stelle überwacht/ The manufacturer's qualit y management system is monitored by the following notified body:

Bureau Veritas S. A. Nr./No. 0062 67/71, Boulevard du Château, 92200 Neuilly-sur-Seine, Fran ce

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

Hersteller/Manufacturer: SAMSON AG, Weismüllerstraße 3, 60314 F rankfurt am Main, Germany

Frankfurt am Main, 15. Dezember 2016/15 December 2016

iron-Body ab/from DN100, Fluide/Fluids G2, L1, L2

DIN/ANSI, Geh. Stahl u.a./Body Ste el etc., alle Fluide/all Fluids

DIN, Gehäuse GG ab DN15 0/Cast iron-Body from DN150; Gehäuse GGG ab

DN100/Sph. gr. iron-Bod y from DN100, Fluide/Fluids G2, L1, L2

DIN/ANSI, Geh. Stahl u.a./Body Ste el etc., alle Fluide/all Fluids

DIN, Geh. Stahl u.a./Body S teel etc., alle Fluide/all Fluids

ANSI, alle Fluide/all Fluids

DIN, Geh. Stahl u.a./Body S teel etc., alle Fluide/all Fluids

ANSI, alle Fluide/all Fluids

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

ANSI, Gehäuse GG Cl125 ab 5"/Cast iron-Body Cl125 from 5", Fluide/Fl uids

Single attenuation plate with welding end

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

Anschweißende/Single atten uation plate multi-stage with welding end

DIN, Gehäuse GG ab DN20 0 PN16/Cast iron-Body from DN200 PN16,

Fluide/Fluids G2, L1, L2

ANSI, NPS 4 Cl 900 und NPS 12 Cl 600, alle Fluide

ANSI, NPS 4 Cl 900 and NPS 12 Cl 600, all fluids

G2, L1, L2

2014/68/EU

Modul H/

Module H

15 May 2014

Bureau Veritas

vom/of

0062

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

SAMSON AKTIENGESELLSCHAFT Weismüllerstraße 3 60314 Frankfurt am Main

EB 8257 EN 51

Dr. Michael Heß Zentralabteilungsleiter/Head of Central Department Technischer Vertrieb/Technical Sales

Telefon: 069 4009-0 · Tel efax: 069 4009-1507 E-Mail: samson@samson.d e

Revison 03

Page 52

52 EB 8257 EN

Page 53

10.3 Spare parts

1 Body 2 Bonnet (with connecting pipe) 3 Yoke 4 Seat 5 Plug 6 Nut 7 Guide bushing

8 Threaded bushing 9 Stem connector nut

10 Lock nut 11 Spring 12 Washer 13 Stud bolt or expansion bolt 14 Body nut 15 Packing assembly 16 V-ring packing 17 Gasket 19 Bushing 21 Insulating section 22 Bellows seal 24 Guide bushing 26 Label (bellows seal or insulating section) 27 Flange 28 Clamping ring 29 Plug for version with bellows seal 31 Washer 32 Bolt 33 Nut 34 Screw 37 Plug stem with metal bellows 39 Gasket 42 Screw plug (test connection) 44 Ring nut/ring 45 Packing ring 46 Seal

Annex

47 Support 48 Screw 49 Screw 50 Threaded pin 51 Guide ring 52 Ring 53 Snap ring 54 Pressure balancing (PTFE) 55 Pressure balancing (graphite) 60 Yoke assembly 62 Flow divider ST3 63 Clamping element 64 Gasket (shim) 65 Gasket (shim) 67 Graphite ber packing 80 Nameplate 81 Grooved pin 82 Screw 83 Hanger 84 Travel indicator scale 91 Protective cap 92 Castellated nut 93 Expansion sleeve 94 Expansion sleeve 101 Bonnet for version with bellows seal

EB 8257 EN 53

Page 54

11 12

44 50 52

45 46

47 53 48

80 81

16 12

12 11

49 50

45 46 47

51 53

44 50

45 46 47

49 50

44 45

47 53

54 EB 8257 EN

Page 55

21 14

26 81

101

7 17

94 33 14 93

26 81

34 31

27 28

EB 8257 EN 55

Page 56

SAMSON AG · MESS- UND REGELTECHNIK Weismüllerstraße 3 · 60314 Frankfurt am Main, Germany Phone: +49 69 4009-0 · Fax: +49 69 4009-1507 samson@samson.de · www.samson.de

EB 8257 EN

2017-05-15 · English

Samson 3286 Mounting And Operating Instructions

Specifications and Main Features

Frequently Asked Questions

User Manual

1 Safety instructions and measures

1.1 Notes on possible severe personal injury

1.2 Notes on possible personal injury

1.3 Notes on possible property damage

2 Markings on the control valve

2.1 Valve nameplate

2.2 Actuator nameplate

2.3 Material number

Design and principle of operation

3.1 Fail-safe positions

3.2 Versions

3.3 Technical data

4 Measures for preparation

4.1 Unpacking

4.2 Transporting and lifting

4.2.1 Transporting

4.2.2 Lifting

4.3 Storage

4.4 Preparation for installation

5 Mounting and start-up

5.1 Mounting the actuator onto the valve

5.2 Installing the valve into the pipeline

5.2.3 Installing the control valve

5.3 Putting the control valve into operation

5.4 Quick check

6 Operation

6.1 Working in manual mode

7 Servicing

7.2 Replacing gaskets

7.1 Preparing the valve for servicing

7.3 Replacing the packing

7.4 Replacing the seat and plug

7.5 Determining the number of shims required

7.8 Ordering spare parts and operating supplies

8 Malfunctions

8.1 Troubleshooting

8.2 Emergency action

Decommissioning and disassembly

9.1 Decommissioning

9.3 Removing the actuator from the valve

9.4 Disposal

10 Annex

10.1 After-sales service

10.3 Spare parts