Samson 3525 Mounting And Operating Instructions
Original instructions
Edition March 2017
Type3525 Globe Valve
In combination with an actuator
such as SAMSON Type3571 Pneumatic Actuator
ANSI version
Mounting and
Operating Instructions
EB 8823 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
future reference.
Î If you have any questions about these instructions, contact SAMSON‘s After-sales Service
Department (samson@samsongroupna.com).
Referenced documentation
The following documents apply in addition to these mounting and operating instructions:
− Mounting and operating instructions for mounted actuator, e.g. uEB8820 for
Type3571 Pneumatic Actuator
− Mounting and operating instructions for mounted valve accessories (e.g. solenoid valve)
The mounting and operating instructions for all supplied devices are included in the delivery.
The latest versions of the documents are available on our website at
uwww.samsoncontrols.com.
Denition 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 8823 EN
!
NOTICE
Property damage or malfunction
Note
Additional information
Tip
Recommended action
Contents
1 Safety instructions and safety measures .........................................................5
1.1 Notes on possible severe personal injury .........................................................7
1.2 Notes on possible personal injury ...................................................................7
1.3 Notes on possible property damage ................................................................9
2 Markings on the control valve ......................................................................10
2.1 Valve nameplate ..........................................................................................10
2.2 Actuator nameplate ......................................................................................11
2.3 Material number ..........................................................................................11
3 Design and principle of operation ................................................................12
3.1 Fail-safe positions ........................................................................................14
3.2 Technical data .............................................................................................15
4 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 .......................................................................................................23
4.4 Preparation for installation ............................................................................24
5 Mounting and start-up ................................................................................. 26
5.1 Mounting the actuator onto the valve .............................................................26
5.2 Installing the valve into the pipeline ...............................................................26
5.2.1 Checking the installation conditions ...............................................................26
5.2.2 Additional ttings .........................................................................................28
5.2.3 Installing the control valve .............................................................................28
5.3 Quick check ................................................................................................29
6 Operation ...................................................................................................30
6.1 Reversing the ow direction ..........................................................................30
7 Maintenance ...............................................................................................32
7.1 Standard version..........................................................................................33
7.1.1 Replacing the O-rings ..................................................................................33
7.1.2 Replacing the packing ..................................................................................36
7.1.3 Replacing the seat and plug ..........................................................................38
7.1.4 Tools and tightening torques..........................................................................39
EB 8823 EN 3
Contents
7.2 Compact version ..........................................................................................40
7.2.1 Replacing the O-rings ..................................................................................40
7.2.2 Replacing the packing ..................................................................................40
7.2.3 Replacing the seat and plug ..........................................................................42
7.2.4 Tools and tightening torques..........................................................................44
7.3 Preparation for return shipment ..................................................................... 44
7.4 Ordering spare parts and operating supplies .................................................45
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 Appendix ....................................................................................................50
10.1 Customer inquiries .......................................................................................50
10.2 Certicates ..................................................................................................50
10.3 Spare parts .................................................................................................52
4 EB 8823 EN
Safety instructions and safety measures
1 Safety instructions and safety measures
Intended use
The SAMSON Type3525 Globe Valve in combination with an actuator (e.g. Type3571
Pneumatic Actuator) is designed to regulate the ow rate, pressure or temperature of liquids,
gases or vapors. The valve is designed for use in high-pressure on/off applications in up-
stream and midstream oil and gas production.
The valve with its actuator is designed to operate under exactly dened conditions (e.g. oper-
ating 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. Ac-
cording to these mounting and operating instructions, trained personnel refers to individuals
who are able to judge the work they are assigned to and recognize possible hazards due to
their specialized training, their knowledge and experience as well as their knowledge of the
applicable standards.
EB 8823 EN 5
Safety instructions and safety measures
Personal protective equipment
We recommend wearing the following protective equipment depending on the process medi-
um:
− Protective clothing, gloves and eyewear in applications with hot, cold and/or corrosive
media when working near or on the valve
− 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. Furthermore, the
control valve may no longer meet the requirements for its intended use.
Safety devices
Upon supply air or control signal failure, the valve moves to its fail-safe position (see 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 maintenance.
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 to the operating
personnel and to instruct them in proper operation. Furthermore, operators must ensure that
operating personnel or third persons are not exposed to any danger.
Responsibilities of operating personnel
Operating personnel must read and understand these mounting and operating instructions as
well as the specied hazard statements, warning and caution notes. Furthermore, the operat-
ing personnel must be familiar with the applicable health, safety and accident prevention
regulations and comply with them.
6 EB 8823 EN
Safety instructions and safety measures
Referenced standards and regulations
The SAMSON Type3525 Globe Valve complies with the requirements of ASMEB16.34.
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 con-
cerned and 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 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 vent plugs.
Î Wear eye protection when working in close proximity to the control valve.
EB 8823 EN 7
Safety instructions and safety measures
!
WARNING
Risk of personal injury due to sudden escape of process medium.
The valve has a safety bleed to detect damaged or worn O-rings. The process medium
may escape suddenly and at high pressure.
Î Wear protective clothing, gloves and eyewear when working near or on the valve.
Î Do not stay in the range of the safety bleed longer than necessary.
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, 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 gloves.
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 preloaded
springs (see associated actuator documentation).
8 EB 8823 EN
Safety instructions and safety measures
1.3 Notes on possible property damage
!
NOTICE
Risk of valve damage due to contamination (e.g. solid particles) in the pipeline.
The plant operator is responsible for cleaning the pipelines.
Î Flush the pipelines before start-up.
Î Observe the maximum permissible pressure for both the 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.
Excessively tightened torques lead to parts wearing out quicker. Parts that are too loose
may cause leakage.
Î Observe the specied tightening torques (see Table5 and Table6).
Risk of valve damage due to the use of unsuitable lubricants.
The lubricants to be used depend on the valve material. Unsuitable lubricants may cor-
rode and damage the valve surface.
Î Only use lubricants approved by SAMSON (see parts list).
EB 8823 EN 9
Markings on the control valve
2 Markings on the control valve
2.1 Valve nameplate
18
12
17
5
6
9
USA
Made in
SAMSON
10
13
7
14
2
15 16
11
3
4
8
2 Type designation
3 Type version
C: compact · S: standard
4 –
5 Material
6 Year of manufacture
7 Order number with modication index
8 Item in order
9 Conformity
10 Nominal size (NPS)
11 Pressure rating (Cl.)
12 For Intermediate Rating Standard Class: pressure and lower temperature limit
For other pressure ratings: lower temperature limit
13 Flow coefcient
14 Characteristic:
%: equal percentage · Lin: linear
15 Seat/plug sealing:
ME: metal
ST: metal base material stellited
®
or base material pure Stellite
®
TC: tungsten carbide
16 Option code for trim identication (stem, plug, seat)
17 For Intermediate Rating Standard Class: pressure and upper temperature limit
For other pressure ratings: upper temperature limit
18 Not used
Fig.1: Type3525 nameplate
10 EB 8823 EN
Markings on the control valve
The valve nameplate is afxed to the rear of
the body.
80
Fig.2: Nameplate at the body
80
2.2 Actuator nameplate
2.3 Material number
The seat and plug of the valves have an article number written on them. Specifying this
article number, you can contact us to nd out
which material is used. Additionally, a seat
code is used to identify the trim material.
This seat code is specied on the nameplate
(seat/plug seal, 13). For more details on the
nameplate, see section2.1.
Standard version
Seat code Material
10 A351CF3M
11 Stellite
12 A747 CB7Cu1 H1150 DBL
14
®
6
WC/TC (HW-Co)/A747 CB7Cu1
H1150DBL
See associated actuator documentation.
Compact version
Seat code Material
11 Stellite
13 WC/TC (HW-Co)/A479 XM-19-H
®
6
EB 8823 EN 11
Design and principle of operation
3 Design and principle of oper-
ation
The single-seated Type3525 Globe Valve is
combined with a SAMSON Type3571
Pneumatic Actuator (see Fig.4).
The seat (4) and plug with plug stem (5) are
assembled in the body (1). The plug stem is
connected to the actuator stem (A7) by the
stem connector clamps (A26) and is sealed
by a spring-loaded V-ring packing (16). The
springs in the pneumatic actuator (A) 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. The standard valve body version normally operates
in the ow-to-open direction (FTO). The medium ows across the plug from bottom to
top. The compact valve body versions normally operate in the ow-to-close direction
(FTC). The medium ows across the plug
from top to bottom.
The valves have a safety bleed to detect
damaged or worn O-rings.
A rise in signal pressure causes the force acting on the diaphragm in the actuator to in-
crease. The springs are compressed. De-
pending 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.
There are three versions available:
− Standard globe valve with anges (see
Fig.3) or threaded ends
− Compact globe valve with threaded ends
− Compact T-pattern valve with threaded
ends (see Fig.5)
Standard globe valves >Class900 with FKM
O-ring are equipped with an additional support ring (244) which is inserted into the
groove of the bottom O-ring (17).
Compact T-pattern valves are equipped with
a screw plug (112). The screw plug can be
positioned either at the bottom outlet or –
depending on the ow direction – at the side
outlet. It must not be positioned at the inlet.
Actuators
In these instructions, the combination with a
Type3571 Pneumatic Actuator is described.
The pneumatic actuator for the standard version can be replaced by another Type3571
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.
12 EB 8823 EN
Design and principle of operation
244
Fig.3: Standard version
Type3525 Globe
Valve with Type3571
Pneumatic Actuator
83
84
60
A28
224
7
17
82
2
16
12
15
11
Safety bleed
36
5
29
17
17
4
127
1
1 Body
2 Bonnet
4 Seat
5 Plug (29, 36)
7 Guide bushing
11 Spring
12 Washer
15 Packing (11, 12, 16)
16 V-ring packing
17 O-ring
29 Plug head
EB 8823 EN 13
36 Plug stem
60 Yoke assembly with
travel indicator
(82, 83, 84)
82 Screw
83 Hanger
84 Travel indicator scale
127 Seat ring gasket
224 Tab washer
244 Support ring
A7 Actuator stem
A28 Stem connector clamp
Fig.4: Bonnet for standard
version >Class900
with FKM O-ring
Design and principle of operation
A16
16
15
12
11
7
17
127
A7
S
A28
92
3
2
36
29
4
1
112
1 Body
2 Bonnet
3 Yoke
4 Seat
5 Plug (29, 36)
7 Guide bushing
11 Spring
12 Washer
15 Packing (11, 12, 16)
16 V-ring packing
17 O-ring
29 Plug head
36 Plug stem
92 Lock nut
5
112 Screw plug
127 Seat ring gasket
A7 Actuator stem
A16 Vent plug
A28 Stem connector clamp
S Signal pressure connection
3.1 Fail-safe positions
The fail-safe position depends on the actua-
tor used.
Depending on how the compression springs
are arranged in the pneumatic actuator, the
valve has two different fail-safe positions:
Actuator stem extends
When the signal pressure is reduced or the
air supply fails, the springs move the actuator stem downward and close the valve. The
valve opens when the signal pressure is in-
Fig.5: Compact version Type3525
T-pattern Valve with Type3571
Pneumatic Actuator
creased enough to overcome the force exerted by the springs.
Actuator stem retracts
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.
14 EB 8823 EN
Design and principle of operation
3.2 Technical data
The nameplates on the valve and actuator
provide information on the control valve ver-
sion. See section2.1 and the actuator docu-
mentation.
Note
More information is available in Data Sheet
uT8823.
Temperature range
The valve version with an HNBR O-ring is
designed for a temperature range from –50
to +300°F (–46 to +149°C). By using an
FKM O-ring the temperature range can be
extended to –10 to +400°F (–23 to
+204°C). In case of oils that cause severe
swelling an FKM O-ring is to be used.
!
WARNING
Risk of hearing loss or deafness due to loud
noise.
Wear hearing protection when working near
the valve.
Dimensions and weights
Table1 and Table2 provide a summary of
the dimensions and weights of the standard
and compact version of Type3525 Valve.
The lengths and heights are shown in the dimensional drawings on p.16 (standard
version) and p.17 (compact version).
Leakage class
The leakage class according to ANSI/
FCI70-2 is IV for all sealing materials of the
seat/plug sealing (see pos. 12 on nameplate: ME, ST, TC).
Noise emission
SAMSON is unable to make general state-
ments about noise emission as it depends on
the valve version, plant facilities and process
medium. On request, SAMSON can perform
calculations according to IEC60534,
Part8-3 and Part8-4 or VDMA24422 (edition89).
EB 8823 EN 15
Design and principle of operation
L
H2
H1
H2
H1
Table1: Dimensions of Type3525 Valve · standard version
NPS 1 2 3
Body
type
Version Standard globe valve
Connection RF RJF NPT RF RJF NPT RF RJF
Class600
Class900
L
Class1500
Class1700
H1
H2
Dimensional drawings
in 8.27 8.27 – 11.26 11.38 9.06 13.27 13.39
mm 210 210 – 286 289 230 337 340
in 10.75 10.75 6.26 13.39 13.50 9.06 15.24 15.35
mm 273 273 159 340 343 230 387 390
in 10.75 10.75 6.10 13.39 13.50 9.06 15.98 16.10
mm 273 273 155 340 343 230 406 409
in
– –
mm 155 230
in 8.70 9.21 9.21
mm 221 234 234
in 1.85 2.95 2.95
mm 47 75 75
6.10
– –
9.06
– –
Standard globe valve, NPS1 to 3, anges Standard globe valve, NPS1 to 2,
16 EB 8823 EN
L
threaded ends
Design and principle of operation
L
H2
H1
L
H2
H1
Table2: Dimensions of Type3525 Valve · compact versions
NPS 1
Body
type
Version
Compact
globe valve
Compact
T-pattern valve
Connection NPT NPT
in
Class600
– –
mm
L
Class900
mm 119 119
in 4.69 4.69
Class1500
Class1700
in
– –
mm
1)
1)
in 6.18 6.18
H1
mm 157 157
H2
in 1.69 2.36
mm 43 60
1)
Length without threaded stopper. This length can be extended by approx. 1.14 in/29mm depend-
1)
1)
ing on the position of the threaded stopper.
Dimensional drawings
Compact globe valve, NPS1 Compact T-pattern valve, NPS1
EB 8823 EN 17
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