Samson 3510 Mounting And Operating Instructions
Mounting and
Operating Instructions
EB 8091-1 EN
Translation of original instructions
Edition September 2016
Type3510-1 (left) and Type3510-7 (right) Pneumatic Control Valves
Type3510 Micro-ow Valve
In combination with an actuator,
e.g. a SAMSON Type3271 or Type3277 Pneumatic Actuator
ANSI version
2 EB 8091-1 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 8091-1 EN 3
1 Safety instructions and measures ...................................................................5
1.1 Notes on possible severe personal injury .........................................................7
1.2 Notes on possible personal injury ...................................................................8
1.3 Notes on possible property damage ................................................................9
2 Markings on the control valve ......................................................................10
2.1 Body inscription ...........................................................................................10
2.2 Actuator nameplate ......................................................................................11
2.3 Material number ..........................................................................................11
3 Design and principle of operation ................................................................12
3.1 Fail-safe positions ........................................................................................12
3.2 Versions ......................................................................................................14
3.3 Technical data .............................................................................................14
4 Measures for preparation ............................................................................20
4.1 Unpacking ..................................................................................................20
4.2 Transporting and lifting ................................................................................20
4.2.1 Transporting ................................................................................................20
4.2.2 Lifting ..........................................................................................................20
4.3 Storage .......................................................................................................21
4.4 Preparation for installation ............................................................................21
5 Mounting and start-up ................................................................................. 23
5.1 Mounting the actuator onto the valve .............................................................23
5.2 Installing the valve into the pipeline ...............................................................23
5.2.1 Checking the installation conditions ...............................................................23
5.2.2 Additional ttings .........................................................................................25
5.2.3 Installing the control valve .............................................................................25
5.3 Quick check ................................................................................................26
6 Operation ...................................................................................................28
6.1 Working in manual mode ............................................................................. 28
7 Servicing.....................................................................................................30
7.1 Replacing the gasket ....................................................................................31
7.1.1 Standard version..........................................................................................31
7.1.2 Version with insulating section .......................................................................31
4 EB 8091-1 EN
Contents
7.1.3 Version with bellows seal ..............................................................................34
7.2 Replacing the packing ..................................................................................36
7.3 Replacing the seat and plug ..........................................................................38
7.3.1 Standard version..........................................................................................38
7.3.2 Version with insulating section .......................................................................39
7.4 Preparation for return shipment ..................................................................... 40
7.5 Ordering spare parts and operating supplies .................................................41
8 Malfunctions ...............................................................................................42
8.1 Troubleshooting ...........................................................................................42
8.2 Emergency action ........................................................................................43
9 Decommissioning and disassembly ..............................................................44
9.1 Decommissioning .........................................................................................44
9.2 Removing the valve from the pipeline .............................................................44
9.3 Removing the actuator from the valve ............................................................45
9.4 Disposal ......................................................................................................45
10 Appendix ....................................................................................................45
10.1 After-sales service ........................................................................................45
10.2 Spare parts .................................................................................................46
EB 8091-1 EN 5
Safety instructions and measures
1 Safety instructions and measures
Intended use
The SAMSON Type3510 Micro-ow 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, gases or vapors. The micro-ow valve is suitable for controlling low ow
rates, e.g. in pilot plants and technical research facilities. 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 applications 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 8091-1 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 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 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. 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 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 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 specied in them. Furthermore, the operating personnel must be familiar with the applicable health, safety and accident prevention regulations and comply with them.
EB 8091-1 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.
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. uEB8310-1 for
Type3271 and Type3277 Pneumatic Actuator with 120cm² actuator area
− Mounting and operating instructions for mounted valve accessories (positioner, solenoid
valve etc.)
− uAB0100 for tools, tightening torques, and lubricant
− For oxygen service: Manual uH01
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.
8 EB 8091-1 EN
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 nger 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. (chemical) burns.
Î If possible, drain any process medium residues from the plant sections concerned as
well as from the valve and any dead cavities.
Î Thoroughly ush the pipelines. The plant operator is responsible for cleaning the
pipelines.
Î Wear protective clothing, safety gloves, and eyewear.
EB 8091-1 EN 9
Safety instructions and measures
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.
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
!
Incorrect control due to a combination of trim parts that do not match each other.
The trim parts (seat, plug, anti-rotation xture, and body gasket) are matched to exactly
t each other. The trim parts are delivered together and marked accordingly (see section2.3).
Î Only install matching trim parts.
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).
10 EB 8091-1 EN
Markings on the control valve
NOTICE
!
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).
2 Markings on the control valve
2.1 Body inscription
SAMSON 3510
1 2
4
6
5
3
8
7
Fig.1: Body inscription
1 Valve size:
DIN: DN · ANSI: NPS· JIS: DN…A/B
2 Pressure rating:
DIN: PN · ANSI: CL · JIS: K
3 Flange/end connection type
4 Material
5 Order number and position number in the order
For after-sales service orders: AA prex
6 Heat number
7 Month and year associated with EAC symbol
8 PED (Pressure Equipment Directive), "Art. 4, Abs. 3"
ID of the notied body, uid group, and category
EB 8091-1 EN 11
Markings on the control valve
The details on the valve version are lasered
onto the valve body (see Fig.1).
2.2 Actuator nameplate
See associated actuator documentation.
2.3 Material number
The valve are marked as follows:
Seat
− Material number
− SAMSON consecutive number
Plug
− Material number
− SAMSON consecutive number
− K
VS
coefcient and characteristic
Anti-rotation xture (on the trim)
Î See Fig.2
− Plug material
− Seat material
− K
VS/CV
− Characteristic
− SAMSON consecutive number
Anti-rotation xture (on the bellows seal)
− Bellows material
− Nominal pressure
Incorrect control due to a combination of
trim parts that do not match each other.
The trim parts (seat, plug, anti-rotation xture, and body gasket) are matched to exactly t each other.
Only install matching trim parts.
1
2
3
4
Plug 1.4404
1.4404
0,025 lin
Seat
kvs
4 711
1 Plug material
2 Seat material
3 K
VS
coefcient and characteristic
4 Consecutive number
Fig.2: Anti-rotation xture (on the trim)
NOTICE
!
12 EB 8091-1 EN
Design and principle of operation
3 Design and principle of oper-
ation
The Type3510 Micro-ow Valve is available
as either a globe or angle valve and is preferably combined with a SAMSON
Type3271 or Type3277 Pneumatic Actuator
with 120cm² actuator area. It can also be
combined with other actuators.
The seat (2.2) and plug (2.1) are installed in
the body (1). The plug stem is connected to
the actuator stem (A7) by the stem connector
and is sealed by an adjustable packing with
PTFE seal rings (34).
The anti-rotation xture (2.4) prevents a
loosening of the screw connection between
the valve body and intermediate piece (4).
Two anti-rotation xtures are used for versions with an insulating section or bellows
seal: one anti-rotation xture between the
body and insulating section/bellows seal as
well as one anti-rotation xture between the
insulating section/bellows seal and intermediate piece.
The springs in the pneumatic actuator are located 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
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.
3.1 Fail-safe positions
The fail-safe position depends on the actuator used.
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 operating
and mounting instructions of the pneumatic
actuator, e.g. uEB8310-1 for Type3271
and Type3277 with 120cm² actuator area.
Tip
EB 8091-1 EN 13
Design and principle of operation
1 Body
2.1 Plug with plug stem
2.2 Seat
2.3 Body gasket
2.4 Anti-rotation xture
4 Intermediate piece
6 Fillister head screw
11 Slotted round nut
12 Threaded bushing (packing
nut)
13 Yoke
14 Travel indicator scale
20 Hexagon nut
34 Packing
A7 Actuator stem
A8 Ring nut
A27.1 Stem connector nut
A27.2 Bearing sleeve (bottom part of
the stem connector)
A27.3 Lock nut
6
2.4
2.3
1
2.2
12
14
13
A8
A7
A27.3
A27.1
A27.2
4
34
11
20
2.1
Fig.3: Type3510 Micro-ow Valve as globe valve with Type3271 Pneumatic Actuator
14 EB 8091-1 EN
Design and principle of operation
3.2 Versions
The modular design allows an insulating section or metal bellows to be tted to the standard valve version.
If valve accessories (e.g. positioner, limit
switch etc.) are to be mounted to the valve
version with anges, we recommend mounting an insulating section or bellows seal. This
provides more space to mount valve accessories.
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.
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 section2.1 and the actuator documentation.
More information is available in Data Sheet
uT8091-1.
Compliance
The Type3510 Valve bears the EAC mark of
conformity:
Temperature range
Depending on the version, the control valve
is designed for a temperature range from 14
to 428°F (–10 to +220°C). The use of an
insulating section or bellows seal extends the
temperature range from –325 to +842°F
(–196 to +450°C). Special materials are
available for temperatures up to 1200°F
(650°C).
Leakage class
Depending on the version, the following
leakage class according to ANSI/FCI70-2
or IEC60534-4 applies:
− Leakage class IV with metal seal
− Leakage class V for high-performance
metal seal
Tip
Note
Note
EB 8091-1 EN 15
Design and principle of operation
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.
WARNING
!
Loading...