Samson 3241 Service manual

Mounting and
Operating Instructions
EB 8012 EN
Translation of original instructions
Edition March 2016
Type3241 Valve with Type3271 Actuator (left) and Type3277 Actuator (right)
Type 3241 Valve
In combination with an actuator,
e.g. a SAMSON Type3271 or Type3277 Pneumatic Actuator
ANSI and JIS version

Denition of signal words
DANGER!
Hazardous situations which, if not
avoided, will result in death or seri-
ous injury
WARNING!
Hazardous situations which, if not
avoided, could result in death or seri-
ous injury
NOTICE
Property damage message or mal-
function
Note:
Additional information
Tip:
Recommended action

2 EB 8012 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.
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
Department (aftersalesser[email protected]).
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.

Contents
EB 8012 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......................................................................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 ........................................................................................16
3.2 Versions ......................................................................................................16
3.3 Technical data .............................................................................................17
4 Preparation.................................................................................................24
4.1 Unpacking ..................................................................................................24
4.2 Transporting and lifting ................................................................................24
4.2.1 Transporting ................................................................................................25
4.2.2 Lifting..........................................................................................................25
4.3 Storage.......................................................................................................28
4.4 Preparation for installation............................................................................29
5 Mounting and start-up.................................................................................30
5.1 Mounting the actuator onto the valve.............................................................30
5.2 Installing the valve into the pipeline ...............................................................31
5.2.1 Checking the installation conditions...............................................................31
5.2.2 Additional ttings.........................................................................................33
5.2.3 Installing the control valve.............................................................................33
5.3 Quick check ................................................................................................34
6 Operation...................................................................................................36
6.1 Working in manual mode.............................................................................36

4 EB 8012 EN
Contents
7 Maintenance ...............................................................................................38
7.1 Replacing the gasket ....................................................................................39
7.1.1 Standard version..........................................................................................39
7.1.2 Version with insulating section or bellows seal................................................41
7.2 Replacing the packing..................................................................................41
7.2.1 Standard version..........................................................................................41
7.2.2 Version with insulating section.......................................................................42
7.3 Replacing the seat and plug..........................................................................44
7.3.1 Standard version..........................................................................................44
7.3.2 Version with insulating section.......................................................................46
7.4 Preparation for return shipment.....................................................................47
7.5 Ordering spare parts and operating supplies .................................................47
8 Malfunctions ...............................................................................................48
8.1 Troubleshooting ...........................................................................................48
8.2 Emergency action ........................................................................................49
9 Decommissioning and disassembly ..............................................................50
9.1 Decommissioning.........................................................................................50
9.2 Removing the valve from the pipeline.............................................................50
9.3 Removing the actuator from the valve ............................................................51
9.4 Disposal......................................................................................................51
10 Appendix....................................................................................................52
10.1 After-sales service........................................................................................52
10.2 Certicates ..................................................................................................53
10.3 Spare parts .................................................................................................59

EB 8012 EN 5
Safety instructions and measures
1 Safety instructions and measures
Intended use
The SAMSON Type3241 Globe Valve in combination with an actuator (e.g. Type3271 or
Type3277 Pneumatic Actuator) is designed to regulate the ow rate, pressure or temperature
of liquids, gases or vapors. The valve with its actuator is designed to operate under exactly
dened conditions (e.g. operating pressure, process medium, temperature). Therefore, opera-
tors 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, 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.
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 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. 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.

6 EB 8012 EN
Safety instructions and 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
−Wear 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 to the product are not authorized by SAMSON.
They are performed at the user's own risk and may lead to safety hazards, for example. Fur-
thermore, the product may no longer meet the requirements for its intended use.
Safety 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 spec-
i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 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, 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 specied hazard statements, warning, and caution notes. Furthermore, the oper-
ating personnel must be familiar with the applicable health, safety and accident prevention
regulations and comply with them.

EB 8012 EN 7
Safety instructions and measures
Referenced standards and regulations
The control valves comply with the requirements of the European Pressure Equipment Direc-
tive 97/23/EC. Valves with a CE marking have a declaration of conformity which includes
information about the applied conformity assessment procedure. This declaration of confor-
mity 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 94/9/EC.
ÎFor connection to the equipotential bonding system, observe the requirements specied in
section 6.3 of EN60079-14:2014-10 (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
Type3271 and Type3277 Actuators
−Mounting and operating instructions for mounted valve accessories (positioner, solenoid
valve etc.)
−uAB0100 for tools and lubricant
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.
ÎBefore starting any work on the control valve, depressurize all plant sections
concerned and the valve.
ÎDrain the process medium from all the plant sections concerned as well as the
valve.
ÎWear personal protective equipment.

8 EB 8012 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 in-
jure hands or ngers if inserted into the valve.
ÎDo not insert hands or nger 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.
Risk of personal injury due to preloaded springs.
Valves in combination with pneumatic actuators with preloaded springs are un-
der tension. 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
preloaded 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, depend-
ing on its properties, may lead to personal injury, e.g. (chemical) burns.
ÎIf possible, drain the process medium from all the plant sections concerned
and the valve.
ÎWear protective clothing, gloves, and eyewear.

EB 8012 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.
ÎAllow components and pipelines to cool down or heat up.
ÎWear protective clothing and gloves.
1.3 Notes on possible property damage
NOTICE
Risk of valve damage due to contamination (e.g. solid particles) in the pipe-
line.
The plant engineering company is responsible for cleaning the pipelines in the
plant.
ÎFlush the pipelines before start-up.
ÎObserve 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 dened properties.
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. Excessive-
ly 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).

10 EB 8012 EN
Safety instructions and measures
NOTICE
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 corrode and damage the valve surface.
ÎOnly use lubricants approved by SAMSON (uAB0100).

EB 8012 EN 11
Safety instructions and measures

12 EB 8012 EN
Markings on the control valve
2 Markings on the control valve
2.1 Valve nameplate
6 8
12 13
10 11
14 15 16 17 18
1…5 9
SAMSON
20
21
19
Fig.1: Valve nameplate
1…5 PED (Pressure Equipment Directive), "Art. 3, Abs. 3"
ID of the notied body, uid group, and category
6 Type designation
8Material
9Year of manufacture
10 Valve size:
DIN: DN · ANSI: NPS· JIS: DN…A/B
11 Pressure rating:
DIN: PN · ANSI: CL · JIS: K
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:
DIN: KVS · ANSI: CV · JIS: CV
15 Characteristic:
%: equal percentage · Lin: linear · NO/NC: quick opening
16 Seat/plug seal:
ME: metal (see section3.3)
HA: carbide metal
ST: Stellite® facing
KE: ceramic
PT: soft seal with PTFE
PK: soft seal with PEEK
17 Seat code (trim material) · On request
18 Pressure balancing:
DIN: D · ANSI: B · JIS: B
19 Flow divider:
1: StI · 3: StIII
20 Country of origin
21 PSA version

EB 8012 EN 13
Markings on the control valve
The valve nameplate (80) in valve sizes
NPS½ to 6 is afxed to the ange (Fig.2).
The valve nameplate in valve sizes NPS8
and larger is located on the yoke (Fig.3).
80
80
Fig.2: Nameplate on
the ange
Fig.3: Nameplate on
the yoke
2.2 Actuator nameplate
See associated actuator documentation.
2.3 Material number
The seat and plug of the valves have an arti-
cle 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). For more details on the nameplate, see
section2.1.

14 EB 8012 EN
Design and principle of operation
3 Design and principle of oper-
ation
The single-seated Type3241 Globe Valve is
preferably combined with a SAMSON
Type3271 or Type3277 Pneumatic Actuator
(see Fig.4). It can also be combined with
other actuators.
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 lo-
cated either above or below the diaphragm
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 deter-
mined 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.

EB 8012 EN 15
Design and principle of operation
1
5
4
16
11
3
84
8
9
10
14
2
17
92
A
2
84
10
A26
9
8
16
11
A8
A7
14
17
1
4
5
1 Body
2 Flange
3Yoke
4 Seat
5 Plug (with plug stem)
8Threaded bushing (packing nut)
9Stem connector nut
10 Lock nut
11 Spring
14 Nuts
16 Packing
17 Body gasket
84 Travel indicator scale
92 Castellated nut
A Actuator
A7 Actuator stem
A8 Ring nut
A26 Stem connector clamps
Fig.4: Type3241‑1 Control Valve with
Type3271 Pneumatic Actuator, body
up to NPS6
Fig.5: Type3241 Valve, body NPS8
to 12

16 EB 8012 EN
Design and principle of operation
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 (FA)
When the signal pressure is reduced or the
air supply fails, the springs move the actua-
tor stem downward and close the valve. The
valve opens when the signal pressure is in-
creased enough to overcome the force exert-
ed by the springs.
Actuator stem retracts (FE)
When the signal pressure is reduced or the
air supply fails, the springs move the actua-
tor stem upwards and open the valve. The
valve closes when the signal pressure is in-
creased enough to overcome the force exert-
ed 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 sec-
tion or metal bellows to be tted to the stan-
dard valve version.
Micro-ow valve version
In the micro-ow valve version, a micro-trim
element is installed in the valve body instead
of the usual seat/plug assembly (Fig.6).
5b
5a
4d
4c
4b
4a
4a Seat body
4b Spring
4c Seat
4d Nut
5a Plug stem
5b Plug
Fig.6: Micro-trim element

EB 8012 EN 17
Design and principle of operation
Actuators
In these instructions, the preferable combina-
tion with a Type3271 or Type3277 Pneu-
matic 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.
ÎObserve 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 ac-
tuator must be preloaded so that the
travel ranges match. See associated
actuator documentation.
The basic pneumatic actuator can be re-
placed by a pneumatic actuator with addi-
tional handwheel or by an electric actuator.
3.3 Technical data
The nameplates on the valve and actuator
provide information on the control valve ver-
sion. See section2.1 and the actuator docu-
mentation.
Note:
More information is available in Da-
ta Sheet uT8012.
Compliance
The Type3241 Valve bears both the CE and
EAC marks of conformity.
Temperature range
Depending on the version, the control valve
is designed for a temperature range from
–10 to +220°C (14 to 428°F). The use of
an insulating section or bellows seal extends
the temperature range from –196 to
+450°C (–325 to +842°F).
Leakage class
Depending on the version, the following
leakage class applies:
Seal (16 on name-
plate) ME, ST ME, ST PT, PK
Pressure balancing
(18 on nameplate) –D/B –
Leakage class (ac-
cording to ANSI/
FCI70-2)
Min. IV Min. IV VI
Noise emission
SAMSON is unable to make general state-
ments about noise emission as it depends on
the valve version, plant facilities, and pro-
cess medium. On request, SAMSON can
perform calculations according to
IEC60534, Part8-3 and Part8-4 or VD-
MA24422 (edition 89).
WARNING!
Risk of hearing loss or deafness due
to loud noise.
Wear hearing protection when work-
ing near the valve.



18 EB 8012 EN
Design and principle of operation
Dimensions and weights
Table1 to Table3 provide a summary of the dimensions and weights of the standard version
of Type3241 Valve. Table4 and Table5 show the dimensions and weights for the
Type3241 Valve with insulating section or bellows seal. The lengths and heights in the di-
mensional drawings are shown on p.22.
Table1: Dimensions of Type3241 Valve, up to NPS6 (DN150)
Valve
NPS ½ ¾ 1 1½ 2 2½ 3 4 6
DN 15 20 25 40 50 65 80 100 150
NPT ½ ¾ 1 1½ 2 – – – –
Length
L 1)
Class125
and 150
in 7.25 7.25 7.25 8.75 10.00 10.88 11.75 13.88 17.75
mm 184 184 184 222 254 276 298 352 451
Class 300 in 7.50 7.62 7.75 9.25 10.50 11.50 12.50 14.50 18.62
mm 190 194 197 235 267 292 318 368 473
H1 for
actua-
tor
≤750cm² in 8.74 8.78 10.31 13.94 15.35
mm 222 223 262 354 390
1000cm²
1400-60cm²
in –16.26 17.72
mm 413 450
1400-
120cm²
2800cm²
in
–
mm
H2 for
version
Cast steel in 1.73 1.73 1.73 2.83 2.83 3.86 3.86 4.65 6.89
mm 44 44 44 72 72 98 98 118 175
Forged steel in 2.1 –2.76 3.62 3.86 –5.05 – –
mm 53 –70 92 98 – 128 – –
1) Face-to-face dimensions according to ANSI/ISA75.08.01

EB 8012 EN 19
Design and principle of operation
Table2: Dimensions of Type3241 Valve, NPS8 (DN200) and larger
Valve
NPS 8 10 10 10 12
DN 200 250/cast iron
250
up to 200 mm
seat bore
250
seat bore 250
mm and larg-
er
300
Length
L 1)
Class125
and 150
in 21.38 26.50 26.50 26.50 29.00
mm 543 673 673 673 737
Class 300 in 22.38 27.88 27.88 27.88 30.50
mm 568 708 708 708 775
H4 in 15.35 15.35 17.76 17.76 25.67
mm 390 390 451 451 652
H8 2)
for ac-
tuator
1000cm²
1400-
60cm²
in 16.46 16.46 16.46 19.80 19.80
mm 418 418 418 503 503
1400-
120cm²
2800cm²
in 19.80 19.80 19.80 25.59 25.59
mm 503 503 503 650 650
H2 in 9.65 10.63 12.20 12.20 14.57
mm 245 270 310 310 370
1) Face-to-face dimensions according to ANSI/ISA75.08.01
2) H8 increases by 6.69“ (170mm) for valves with CV 290, 420 or 735 (KVS 250, 360 or 630) and 60mm rated
travel operating with overtravel
Table3: Weights for Type3241 Valve
Valve NPS ½ ¾ 1 1½ 2 2½ 3 4 6 8 10 12
DN 15 20 25 40 50 65 80 100 150 200 250 300
Weight with-
out actuator
lbs 15 18 20 35 44 71 82 137 287 1096 1892 2535
kg 7 8 9 16 20 32 37 62 130 497 858 1150

20 EB 8012 EN
Design and principle of operation
Table4: Dimensions and weights for the Type3241 Valve with insulating section or bellows
seal up to NPS6 (DN150)
Valve size NPS ½ ¾ 1 1½ 2 2½ 3 4 6
DN 15 20 25 40 50 65 80 100 150
Insulating
section or
bellows seal
H4 for
actua-
tor
≤750cm²
Short in 16.10 16.14 17.76 25.04 26.46
mm 409 410 451 636 672
Long in 28.07 28.11 29.72 34.53 35.94
mm 713 714 755 877 913
1000cm²
1400-60cm²
Short in –27.36 28.82
mm 695 732
Long in –36.85 38.31
mm 936 973
1400-
120cm²/
2800cm²
Short
Long
in
–
mm
Weight without
actuator (approx.)
Short lbs 22 24 26 49 57 88 99 176 353
kg 10 11 12 22 26 40 45 80 160
Long lbs 31 33 35 57 66 97 108 194 370
kg 14 15 16 26 30 44 49 88 168