Samson 3248 Service manual

Translation of original instructions
EB 8093-1 EN
Edition November 2020
Type3248 Valve · ANSI version
In combination with an actuator,
e.g. a Type3271 or Type3277 Pneumatic Actuator

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]).
Documents relating to the device, such as the mounting and operating
instructions, are available on our website at www.samsongroup.com >
Service & Support > Downloads > Documentation.
Denition 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 8093-1 EN

Contents
EB 8093-1 EN
1 Safety instructions and measures ................................................................1-1
1.1 Notes on possible severe personal injury ......................................................1-5
1.2 Notes on possible personal injury ................................................................1-6
1.3 Notes on possible property damage.............................................................1-7
1.4 Warnings on the device...............................................................................1-9
2 Markings on the device ..............................................................................2-1
2.1 Valve nameplate .........................................................................................2-1
2.2 Actuator nameplate.....................................................................................2-2
2.3 Material identication number .....................................................................2-2
3 Design and principle of operation ...............................................................3-1
3.1 Fail-safe positions .......................................................................................3-4
3.2 Versions .....................................................................................................3-4
3.3 Additional ttings........................................................................................3-5
3.4 Valve accessories........................................................................................3-5
3.5 Technical data ............................................................................................3-5
4 Shipment and on-site transport ...................................................................4-1
4.1 Accepting the delivered goods .....................................................................4-1
4.2 Removing the packaging from the valve........................................................4-1
4.3 Transporting and lifting the valve..................................................................4-1
4.3.1 Transporting the valve .................................................................................4-2
4.3.2 Lifting the valve...........................................................................................4-3
4.4 Storing the valve.........................................................................................4-8
5 Installation.................................................................................................5-1
5.1 Installation conditions..................................................................................5-1
5.2 Preparation for installation...........................................................................5-2
5.3 Mounting the device....................................................................................5-3
5.3.1 Installing the valve into the pipeline ..............................................................5-4
5.3.2 Removing the protective cover......................................................................5-4
5.3.3 Mounting the actuator onto the valve............................................................5-7
5.4 Testing the installed valve.............................................................................5-8
5.4.1 Leak test.....................................................................................................5-9
5.4.2 Travel motion............................................................................................5-10
5.4.3 Fail-safe position.......................................................................................5-10
5.4.4 Pressure test..............................................................................................5-10
6 Start-up .....................................................................................................6-1

Contents
EB 8093-1 EN
7 Operation..................................................................................................7-1
7.1 Normal operation .......................................................................................7-2
7.2 Manual operation .......................................................................................7-2
8 Malfunctions ..............................................................................................8-1
8.1 Troubleshooting ..........................................................................................8-1
8.2 Emergency action .......................................................................................8-2
9 Servicing....................................................................................................9-1
9.1 Periodic testing ...........................................................................................9-3
9.2 Preparing the valve for service work.............................................................9-5
9.3 Mounting the valve after service work...........................................................9-5
9.4 Service work...............................................................................................9-5
9.4.1 Replacing the gasket ...................................................................................9-6
9.4.2 Replacing the packing.................................................................................9-8
9.4.3 Replacing the seat and plug.......................................................................9-10
9.4.4 Replacing the bellows seal.........................................................................9-10
9.5 Ordering spare parts and operating supplies ..............................................9-10
10 Decommissioning .....................................................................................10-1
11 Removal ..................................................................................................11-1
11.1 Removing the valve from the pipeline..........................................................11-1
11.2 Removing the actuator from the valve .........................................................11-2
12 Repairs ....................................................................................................12-1
12.1 Returning devices to SAMSON ..................................................................12-1
13 Disposal...................................................................................................13-1
14 Certicates...............................................................................................14-1
15 Annex......................................................................................................15-1
15.1 Tightening torques, lubricants and tools ......................................................15-1
15.2 Spare parts ..............................................................................................15-1
15.3 After-sales service.....................................................................................15-4

EB 8093-1 EN 1-1
Safety instructions and measures
1 Safety instructions and measures
Intended use
The SAMSON Type3248 Globe and Angle 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 or gases in cryogenic applications. For this purpose, the valves can
be welded into vacuum-insulated pipelines or cold boxes. The valve with its actuator is de-
signed to operate under exactly dened conditions (e.g. operating pressure, process medi-
um, temperature). Therefore, operators must ensure that the control valve is only used in op-
erating conditions 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 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 connected to the 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
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 must 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.
Welding operations must only be performed by personnel who has the necessary qualica-
tion to perform the welding procedure applied and handle the materials used.

1-2 EB 8093-1 EN
Safety instructions and measures
Explosion-protected versions of this device must be operated only by personnel who has un-
dergone special training or instructions or who is authorized to work on explosion-protected
devices in hazardous areas.
Personal protective equipment
We recommend checking the hazards posed by the process medium being used (e.g.
uGESTIS (CLP) hazardous substances database). Depending on the process medium and/
or the activity, the protective equipment required includes:
− Protective clothing, gloves, eye protection and respiratory protection in applications with
hot, cold and/or corrosive media
− Wear hearing protection when working near the valve
− Hard hat
− Safety harness when working at height
− Safety footwear, ESD (electrostatic discharge) footwear, if necessary
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 features
The fail-safe position of the control valve upon air supply or control signal failure depends on
the actuator used (see associated actuator documentation). When the valve is combined with
a SAMSON Type3271 or Type3277 Pneumatic Actuator, the valve moves to a certain fail-
safe position (see the 'Design and principle of operation' section) upon supply air or control
signal failure. 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.
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. Plant
operators and operating personnel must observe all hazard statements, warning and caution
notes in these mounting and operating instructions.

EB 8093-1 EN 1-3
Safety instructions and measures
Hazards resulting from the special working conditions at the installation site of the valve must
be identied in a risk assessment and prevented through the corresponding safety instruc-
tions drawn up by the operator.
Responsibilities of the operator
Operators are responsible for proper use and compliance with the safety regulations. Opera-
tors are obliged to provide these mounting and operating instructions as well as the refer-
enced documents to the operating personnel and to instruct them in proper operation. Fur-
thermore, operators must ensure that operating personnel or third parties are not exposed to
any danger.
Operators are additionally responsible for ensuring that the limits for the product dened in
the technical data are observed. This also applies to the start-up and shutdown procedures.
Start-up and shutdown procedures fall within the scope of the operator's duties and, as such,
are not part of these mounting and operating instructions. SAMSON is unable to make any
statements about these procedures since the operative details (e.g. differential pressures and
temperatures) vary in each individual case and are only known to the operator.
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, operating personnel must be familiar with the applicable
health, safety and accident prevention regulations and comply with them.
Referenced standards, directives and regulations
The control valves comply with the requirements of the European Pressure Equipment Direc-
tive 2014/68/EU and the Machinery Directive 2006/42/EC. Valves with a CE marking
have a declaration of conformity which includes information about the applied conformity
assessment procedure. The 'Certicates' section contains this declaration of conformity.
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.
ÎFor connection to the equipotential bonding system, observe the requirements specied in
section6.4 of EN60079-14 (VDE0165-1).

1-4 EB 8093-1 EN
Safety instructions and measures
Referenced documentation
The following documents apply in addition to these mounting and operating instructions:
− Mounting and operating instructions for the mounted actuator, e.g. uEB8310-X for the
SAMSON Type3271 or Type3277 Pneumatic Actuator
− Mounting and operating instructions for mounted valve accessories (positioner, solenoid
valve etc.)
− uAB0100 for tools, tightening torques and lubricant
− For oxygen service: Manual uH01
− Manual uH02: Appropriate Machinery Components for SAMSON Pneumatic Control
Valves with a Declaration of Conformity of Final Machinery

EB 8093-1 EN 1-5
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. Impermissible pressure or improper
opening can lead to valve components bursting.
ÎObserve the maximum permissible pressure for valve and plant.
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 concerned as well as the
valve.
Risk of injury due to incorrect handling of oxygen or cryogenic gases in applica-
tions.
The Type3248 Valve is frequently used for oxygen service or applications with cryo-
genic gases. Oxygen is a hazardous substance, which reacts quickly, leading to com-
bustion and explosions. Contact with cryogenic gases causes severe frostbite and cold
burns (cryogenic burns). Operating personnel must be trained for these applications.
Unqualied operating personnel expose themselves and others to an increased risk of
injury.
ÎOperating personnel must be sufciently trained and be made aware of the haz-
ards in applications involving oxygen or cryogenic gases.
ÎInstructions and information on how to safely handle devices for oxygen service
can be found in the Manual uH01.
All SAMSON staff receives appropriate training before performing any activities in
connection with oxygen service. SAMSON's After-sales Service also offers such train-
ing courses for service staff to allow them to learn how to handle devices for the above
listed applications correctly and safely.
Tip

1-6 EB 8093-1 EN
Safety instructions and measures
1.2 Notes on possible personal injury
WARNING
!
Risk of burn injuries due to cold components and pipelines.
Depending on the process medium, valve components and pipelines may get extremely
cold and cause cryogenic burns.
ÎAllow components and pipelines to reach ambient temperature.
ÎWear protective clothing and safety gloves.
Risk of hearing loss or deafness due to loud noise.
The noise emissions depend on the valve version, plant facilities and process medium.
ÎWear hearing protection when working near the valve.
Risk of personal injury due to exhaust air being vented.
While the valve is operating, air is vented from the actuator, for example, during
closed-loop operation or when the valve opens or closes.
ÎInstall the control valve in such a way that vent holes are not located at eye level and
the actuator does not vent at eye level in the work position.
ÎUse suitable silencers and vent plugs.
ÎWear eye protection when working in close proximity to the control valve.
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 nger into the yoke while the air supply is connected to the
actuator.
ÎBefore working on the control valve, disconnect and lock the pneumatic air supply
as well as the control signal.
ÎDo not impede the movement of the actuator and plug stem by inserting objects into
the yoke.
ÎBefore unblocking the actuator and plug stem after they have become blocked (e.g.
due to seizing up after remaining in the same position for a long time), release any
stored energy in the actuator (e.g. spring compression). See associated actuator
documentation.

EB 8093-1 EN 1-7
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 medium can ow out of the valve and, depending
on its properties, cause 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, respiratory protection and eye protection.
Risk of personal injury through incorrect operation, use or installation as a result of
information on the valve being illegible.
Over time, markings, labels and nameplates on the valve may become covered with dirt
or become illegible in some other way. As a result, hazards may go unnoticed and the
necessary instructions not followed. There is a risk of personal injury.
ÎKeep all relevant markings and inscriptions on the device in a constantly legible
state.
ÎImmediately renew damaged, missing or incorrect nameplates or labels.

1-8 EB 8093-1 EN
Safety instructions and 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 in the plant.
ÎFlush the pipelines before start-up.
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.
Risk of leakage and valve damage due to excessively high or low tightening torques.
Observe the specied torques when tightening control valve components. Excessive
tightening torques lead to parts wearing out more quickly. 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 surfaces.
ÎOnly use lubricants approved by SAMSON (uAB0100).
Risk of the process medium being contaminated through the use of unsuitable lubri-
cants and/or contaminated tools and components.
ÎIf necessary, keep the valve and the tools used free from solvents and grease.
ÎMake sure that only suitable lubricants are used.

EB 8093-1 EN 1-9
Safety instructions and measures
1.4 Warnings on the device
Warning Meaning of the warning Location on the device
Warning against moving parts
There is a risk of injury to hands or ngers through the
stroking movement of the actuator and plug stem if they
are inserted into the yoke while the air supply is con-
nected to the actuator.

1-10 EB 8093-1 EN

EB 8093-1 EN 2-1
Markings on the device
2 Markings on the device
2.1 Valve nameplate
22
21
20 19
1817
16
151413121110
8
7
6
5
4
2
1
Fig.2-1: Inscriptions on the valve nameplate
Fig.2-1 and the inscription table list all
possible characteristics and options that may
appear on a valve nameplate. Only the
inscriptions relevant to the ordered
Type3248 Valve actually appear on the
nameplate.
Note
Item Inscription meaning
1 Data Matrix code
2 Type designation
4 Material
5 Month and year of manufacture
6 Valve size:
DIN: DN · ANSI: NPS · JIS: DN
7 Pressure rating:
DIN: PN · ANSI: CL · JIS: K
8 Order number/item
10 Flow coefcient:
DIN: KVS · ANSI: CV
11 Characteristic:
%: equal percentage · LIN: linear
mod-lin: modied linear
NO/NC: on/off service
12 Seat-plug seal:
ME: metal · HA: carbide metal
ST: metal base material with Stellite®facing
KE: ceramic · PT: PTFE soft seal · PK: PEEK
soft seal
13 Seat code (trim material): on request
14 Pressure balancing:
DIN: D · ANSI/JIS: B
Version:
M: mixing valve · V: ow-diverting valve
Item Inscription meaning
15 Noise reduction:
1:ow divider(ST)1 · 2:ST2 ·3:ST3
1/PSA:ST1 standard and integrated in
seat for PSA valve
AC-1/AC-2/AC-3/AC-5:AC trim, versions
1 to 5
LK: perforated plug · LK1/LK2/LK3:perfo-
rated plug with ow divider ST1 to ST3
MHC1:multi-hole cage
CC1:Combi Cage · ZT1:Zero Travel
16 Country of origin
17 PSA version:
PSA
18 Cage/seat style:
CC: clamped cage, clamped seat
SF: suspended cage, anged seat
19 CE marking
20 ID of the notied body
PED: Pressure Equipment Directive
G1/G2: gases and vapors
Fluid group1= hazardous
Fluid group2= other
L1: liquids
Fluid group1= hazardous
Fluid group2= other
I/II/III: Category 1 to 3
21 Serial number
22 NE53 (NAMUR Recommendation)

2-2 EB 8093-1 EN
Markings on the device
The nameplate is afxed to the valve bonnet
(see Fig.2-2).
2Valve bonnet
80 Nameplate
80
2
Fig.2-2: Valve nameplate
2.2 Actuator nameplate
See associated actuator documentation.
2.3 Material identication
number
The seat and plug of the valves have an item
number written on them. You can contact us
stating this item number 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.

EB 8093-1 EN 3-1
Design and principle of operation
3 Design and principle of oper-
ation
The Type3248 is available in the following
versions:
− Globe or angle valve with stainless steel
body, NPS1 to 6, Class150 to 300 (see
Fig.3-1)
− Globe or angle valve with stainless steel
body, NPS1 to 6, Class600 (see
Fig.3-2)
A top-entry design is used for these valves.
As a result, the valve does not need to be re-
moved from the pipeline for service work.
The seat (4) and plug with plug stem (5) are
installed in the body (1). The plug stem is
screwed to the plug stem with bellows seal
(37) which is, in turn, screwed to the spacer
stem (71). The stem connector clamps
(A26/27) connect the actuator stem (A7) of
the mounted actuator.
The cryogenic extension bonnet is welded
onto the body (1). Its bottom part consists of
the bellows seal and insulated pipe. A cover
plate can be welded at a specic angle onto
the pipe. The cover plate serves as orienta-
tion during installation into a cold box, for
example.
The plug stem is sealed by the metal bellows
and the packing (15). The metal bellows pre-
vents direct contact of the packing with the
process medium. As a result, the service life
is increased and icing up is prevented. The
test connection at the valve bonnet can be
used to monitor the sealing ability of the bel-
lows. The packing consists of a spring-load-
ed PTFE-carbon V-ring packing.
In the Class150 to 300 version, the valve
bonnet (2) is designed as a yoke (see
Fig.3-1). In the Class600 version, the valve
bonnet (2) is designed as an intermediate
piece. A yoke (3) is fastened onto the valve
bonnet with a castellated nut (92) (see
Fig.3-2).
A protective cover can be mounted in place
of the valve bonnet and actuator. This reduc-
es the overall height of the valve and makes
it easier to transport it. The protective cover
also protects the inside of the bellows seal
against moisture and dirt.
The medium ows through the valve in the
direction indicated by the arrow. The springs
in the pneumatic actuator are located either
above or below the diaphragm depending
on the selected fail-safe action (see sec-
tion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. 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 di-
rection 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.

3-2 EB 8093-1 EN
Design and principle of operation
Fig.3-1: Type3248 Globe Valve with
stainless steel body (Class150
to 300) · With Type3271
Pneumatic Actuator
Cover plate
1 Body (including cryogenic
extension bonnet)
2Valve bonnet
4Seat
5 Plug (with plug stem)
8Threaded bushing (packing
nut)
9Stem connector nut
10 Lock nut
15 Packing
17 Bonnet gasket
37 Plug stem with metal bellows
41 Bellows nut
42 Test connection
71 Spacer stem
A7 Actuator stem
A26/27 Stem connector clamps
1
4
5
37
41
71
42
15
8
217
9
A7
A26/27
10

EB 8093-1 EN 3-3
Design and principle of operation
1Body (including cryogenic exten-
sion bonnet)
2Valve bonnet
3Yoke
4Seat
5 Plug (with plug stem)
8Threaded bushing (packing nut)
9Stem connector nut
10 Lock nut
15 Packing
17 Bonnet gasket
32 Bolt
33 Nut
37 Plug stem with metal bellows
41 Bellows nut
42 Test connection
71 Spacer stem
92 Castellated nut
1
4
5
37
41
42
33
15
8
10
9
71
92
32
2
3
Fig.3-2: Type3248 Angle Valve with stainless steel body, Class600

3-4 EB 8093-1 EN
Design and principle of operation
3.1 Fail-safe positions
The fail-safe position of the control valve up-
on air supply or control signal failure de-
pends on the actuator used (see associated
actuator documentation).
Depending on how the compression springs
are arranged in the SAMSON Type3271
and Type3277 Pneumatic Actuator, the
valve has one of two different fail-safe posi-
tions:
− 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 over-
come 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 over-
come the force exerted by the springs.
The actuator's direction of action can be re-
versed, 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
We recommend the use of positioners with
integrated diagnostic rmware (see sec-
tion3.4) for valves used for on/off service.
The partial stroke test included in this soft-
ware helps prevent a shut-off valve normally
in its end position from seizing up or getting
jammed.
Larger valve sizes
The Type3248 Valve is available up to valve
size NPS8.
Actuators
In these instructions, the preferable combina-
tion with a SAMSON 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.
ÎObserve 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 associ-
ated actuator documentation.
The basic pneumatic actuator can be re-
placed by a pneumatic actuator with addi-
tional handwheel.
Tip
Tip
Note