Samson 3241-1-Gas Service manual

Translation of original instructions
EB 8020-1 EN
Edition February 2020
Type3241-1-Gas and Type3241-7-Gas
Automatic Shut-off Valves for Gases
Valve classD and valve class E
Type3241‑7‑Gas with Type3963 Solenoid Valve and Type3730 Positioner
NOTICE on the scope of this document
These mounting and operating instructions
only apply to valves already in use.
For control valves of the valve class D, refer
to the updated mounting and operating
instructions uEB8020
They can be downloaded from our website
at
uwww.samsongroup.com > Service &
Support > Downloads > Documentation

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. The images shown in
these instructions are for illustration purposes only. The actual product may vary.
ÎFor the safe and proper use of these instructions, read them carefully and keep them for
later reference.
ÎIf you have any questions about these instructions, contact SAMSON‘s After‑sales Service
([e-mail]).
The mounting and operating instructions for the devices are included
in the scope of delivery. The latest documentation is available on our
website at www.samsongroup.com > Service & Support > Downloads >
Documentation.
Definition 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
EB 8020-1 EN

Contents
EB 8020-1 EN
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 device ...............................................................................12
2.1 Nameplate for gas version............................................................................12
2.2 Valve nameplate ..........................................................................................13
2.3 Actuator nameplate......................................................................................14
2.4 Other markings ...........................................................................................14
2.4.1 DVGW register number................................................................................14
2.4.2 Material numbers.........................................................................................14
2.5 Position of marking ......................................................................................14
3 Design and principle of operation ................................................................16
3.1 Fail‑safe positions ........................................................................................19
3.2 Versions ......................................................................................................19
3.3 Technical data .............................................................................................19
3.3.1 Common technical data................................................................................19
3.3.2 Technical data of version for valve classD......................................................23
3.3.3 Technical data of version for valve classE......................................................25
4 Measures for preparation............................................................................27
4.1 Unpacking ..................................................................................................27
4.2 Transporting and lifting ................................................................................27
4.2.1 Transporting ................................................................................................28
4.2.2 Lifting..........................................................................................................28
4.3 Storage.......................................................................................................30
4.4 Preparation for installation............................................................................31
5 Mounting and start-up.................................................................................32
5.1 Mounting the actuator onto the valve.............................................................32
5.2 Installing the valve into the pipeline ...............................................................32
5.2.1 Checking the installation conditions...............................................................32
5.2.2 Additional ttings.........................................................................................33
5.2.3 Installing the control valve.............................................................................34
5.3 Quick check ................................................................................................34
6 Operation...................................................................................................36

Contents
EB 8020-1 EN
7 Servicing.....................................................................................................37
7.1 Replacing the gasket ....................................................................................38
7.2 Other service work.......................................................................................39
7.3 Aligning the V‑port plug...............................................................................39
7.4 Cleaning the strainer....................................................................................40
7.5 Testing the control valve................................................................................40
7.6 Preparation for return shipment.....................................................................40
7.7 Ordering spare parts and operating supplies .................................................40
8 Malfunctions ...............................................................................................43
8.1 Troubleshooting ...........................................................................................43
8.2 Emergency action ........................................................................................44
9 Decommissioning and removal ....................................................................45
9.1 Decommissioning.........................................................................................45
9.2 Removing the valve from the pipeline.............................................................45
9.3 Removing the actuator from the valve ............................................................45
9.4 Disposal......................................................................................................45
10 Annex.........................................................................................................46
10.1 After‑sales service........................................................................................46
10.2 Certicates ..................................................................................................46
10.3 Spare parts .................................................................................................53

EB 8020-1 EN 5
Safety instructions and measures
1 Safety instructions and measures
Intended use
The SAMSON Type3241G Globe Valve in combination with the Type3271 or Type3277
Pneumatic Actuator and a solenoid valve is designed to regulate the ow rate, pressure or
temperature of fuel gases in gas‑consuming equipment.
The valve, actuator and solenoid valve are designed to operate under exactly dened condi‑
tions (e.g. operating pressure, process medium, temperature). Therefore, operators must en‑
sure 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 oth‑
er applications or conditions than specied, contact SAMSON.
SAMSON does not assume any liability for damage resulting from the failure to use the de‑
vice for its intended purpose or for damage caused by external forces or any other external
factors.
ÎRefer 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 by 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 (e.g. Gas Appliances Regulation (EU) 2016/426).
Furthermore, the operating personnel must be specially trained for the correct and safe
handling of fuel gases in gas‑consuming equipment.
SAMSON does not assume any liability for personal injury or property damage caused by
untrained operating personnel.

6 EB 8020-1 EN
Safety instructions and measures
Personal protective equipment
We recommend checking the hazards posed by the process medium being used (e.g.
uGESTIS (CLP) hazardous substances database).
ÎProvide protective equipment (e.g. safety gloves, eye protection) appropriate for the pro‑
cess medium used.
ÎWear hearing protection when working near the valve.
ÎCheck with the plant operator for details on further protective equipment.
Revisions and other modications
Revisions, conversions or other modications of the product are not authorized by SAMSON.
They are performed at the user's own risk and may lead to safety hazards, for example. Fur‑
thermore, the product may no longer meet the requirements for its intended use.
Safety devices
−Upon supply air or control signal failure, the valve moves to its fail‑safe position (see sec‑
tion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).
−Valve classD: the safety control valves are tested according to DINEN161 (2013‑04).
In the event of a malfunction, the valves shut off the gas supply. They meet the strict leak‑
age requirements of Class D.
−Valve classE: the safety control valves are tested according to DINEN161 (1996‑08). In
the event of a malfunction, the valves shut off the gas supply. The valves meet the strict
leakage requirements of Class E and are assigned to Valve Group 2.
Warning against residual hazards
To avoid personal injury or property damage, plant operators and operating personnel must
prevent hazards that could be caused in the control valve by the process medium, the operat‑
ing pressure, the signal pressure or by moving parts by taking appropriate precautions. They
must observe all hazard statements, warning and caution notes in these mounting and oper‑
ating instructions.
We also recommend checking the hazards posed by the process medium being used (e.g.
uGESTIS (CLP) hazardous substances database).
ÎObserve safety measures for handling the device as well as re prevention and explosion
protection measures.

EB 8020-1 EN 7
Safety instructions and measures
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 ex‑
posed 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 specied hazard statements, warnings
and caution notes. Furthermore, the operating personnel must be familiar with the applicable
health, safety and accident prevention regulations and comply with them.
Referenced standards and regulations
−The control valves comply with the requirements of the European Pressure Equipment Di‑
rective 2014/68/EU. Valves with a CE marking have an EU declaration of conformity,
which includes information about the applied conformity assessment procedure. The EU
declaration of conformity is included in the annex of these instructions (see section10.2).
−Valve classD: the control valves meet the requirements of the previously valid European
Gas Appliance Directive 2009/142/EC and the currently valid Gas Appliances Regula‑
tion (EU) 2016/426. The EC type examination certicate and EU declaration of confor‑
mity are included in the annex of these instructions (see section10.2).
−Valve classE: the control valves meet the requirements of the 90/396/EEC. This type ex‑
amination certicate is included in the annex of these instructions (see section10.2).
−The control valves meet the safety, construction and function requirements for automatic
shut‑off valves with gas burners, gas equipment and similar applications according to
DINEN161.
Referenced documentation
The following documents apply in addition to these mounting and operating instructions:
−Mounting and operating instructions for mounted actuator, e.g. uEB8310‑X for
Type3271 and Type3277 Actuators
−Mounting and operating instructions for mounted valve accessories (positioner, solenoid
valve etc.)
−uAB0100 for tools, tightening torques and lubricant

8 EB 8020-1 EN
Safety instructions and measures
1.1 Notes on possible severe personal injury
DANGER
!
Risk of bursting in pressure equipment.
Valves and pipelines are pressure equipment. Improper opening can lead to valve
components bursting.
ÎBefore starting any work on the control valve, depressurize all plant sections affect‑
ed as well as the valve.
ÎDrain the process medium from all the plant sections affected as well as the valve.
ÎWear 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 stem), which can injure
hands or ngers if inserted into the valve.
ÎDo not insert hands or ngers into the yoke while the valve is in operation.
ÎWhile 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.
ÎInstall the control valve in such a way that the actuator does not vent at eye level.
ÎUse suitable silencers and vent plugs.
ÎWear eye protection when working in close proximity to the control valve.

EB 8020-1 EN 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 ten‑
sion. These control valves with SAMSON pneumatic actuators can be identied by the
long bolts protruding from the bottom of the actuator.
ÎBefore 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.
ÎIf possible, drain the process medium from all the plant sections affected and the
valve.
ÎWear protective clothing, safety gloves and eye protection.
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.
ÎAllow components and pipelines to cool down or heat up.
ÎWear 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.
ÎFlush the pipelines before start‑up.
ÎObserve the maximum permissible pressure for valve and plant.

10 EB 8020-1 EN
Safety instructions and measures
NOTICE
!
Risk of valve damage due to unsuitable medium properties.
The valve is sized according to Gas Appliances Regulation (EU) 2016/426 (valve
classD) or the Directive 90/396/EEC (valve classE) for fuel gases.
ÎOnly use the process medium specied for sizing the valve.
Risk of leakage and valve damage due to excessively high or low tightening
torques.
Observe the specied torques on tightening control valve components. Excessively
tightened torques lead to parts wearing out quicker. Parts that are too loose may cause
leakage.
ÎObserve 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.
ÎOnly 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 cor‑
rode and damage the surface.
ÎOnly use lubricants approved by SAMSON (uAB0100).