Samson 3248 Service manual

Mounting and
Operating Instructions
EB 8093 EN
Translation of original instructions
Edition November 2016
Type 3248 Valve
In combination with an actuator,
e.g. a SAMSON Type3271 or Type3277 Pneumatic Actuator
DIN version

2 EB 8093 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.
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

Contents
EB 8093 EN 3
1 Safety instructions and measures ...................................................................5
1.1 Notes on possible severe personal injury .........................................................8
1.2 Notes on possible personal injury ...................................................................9
1.3 Notes on possible property damage..............................................................10
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 ........................................................................................17
3.2 Versions ......................................................................................................17
3.3 Technical data .............................................................................................18
4 Measures for preparation............................................................................24
4.1 Unpacking ..................................................................................................24
4.2 Transporting and lifting ................................................................................24
4.2.1 Transporting ................................................................................................25
4.2.2 Lifting..........................................................................................................26
4.3 Storage.......................................................................................................30
4.4 Preparation for installation............................................................................31
5 Mounting and start-up.................................................................................32
5.1 Installing the valve into the pipeline ...............................................................32
5.1.1 Checking the installation conditions...............................................................32
5.1.2 Additional ttings.........................................................................................34
5.1.3 Installing the control valve.............................................................................34
5.2 Removing the protective cover.......................................................................35
5.3 Mounting the actuator onto the valve.............................................................37
5.4 Quick check ................................................................................................38
6 Operation...................................................................................................40
6.1 Working in manual mode.............................................................................40

4 EB 8093 EN
Contents
7 Servicing.....................................................................................................42
7.1 Replacing the gasket ....................................................................................43
7.1.1 Globe or angle valve, PN16 to 40 ...............................................................43
7.1.2 Globe or angle valve, PN63 and 100...........................................................44
7.2 Replacing the packing..................................................................................45
7.2.1 Globe or angle valve, PN16 to 40 ...............................................................45
7.2.2 Globe or angle valve, PN63 and 100...........................................................46
7.3 Replacing the seat and plug..........................................................................47
7.4 Replacing the bellows seal............................................................................47
7.5 Preparation for return shipment.....................................................................47
7.6 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 ............................................................50
9.4 Disposal......................................................................................................50
10 Appendix....................................................................................................52
10.1 After-sales service........................................................................................52
10.2 Certicates ..................................................................................................52
10.3 Spare parts .................................................................................................55

EB 8093 EN 5
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 ap-
plications 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.
According to these mounting and operating instructions, trained personnel refers to
individuals who are able to judge the work they are assigned to and recognize possible
hazards due to their specialized training, their knowledge and experience as well as their
knowledge of the applicable standards.

6 EB 8093 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 cold or cryogenic 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 feature
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 service work.
Responsibilities of the operator
The operator is responsible for proper operation and compliance with the safety regulations.
Operators are obliged to provide these mounting and operating instructions as well as the
referenced documents to the operating personnel and to instruct them in proper operation.
Furthermore, the operator must ensure that operating personnel or third persons are not 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 hazard statements, warning and caution
notes specied in them. Furthermore, the operating personnel must be familiar with the ap-
plicable health, safety and accident prevention regulations and comply with them.

EB 8093 EN 7
Safety instructions and measures
Referenced standards and regulations
The control valves comply with the requirements of the European Pressure Equipment Direc-
tive 2014/68/EU. Valves with a CE marking have a declaration of conformity, which in-
cludes information about the applied conformity assessment procedure. This declaration of
conformity 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 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 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, tightening torques, and lubricant
−For oxygen service: Manual uH01

8 EB 8093 EN
Safety instructions and measures
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 as well as the valve.
ÎDrain the process medium from all the plant sections concerned as well as the
valve.
ÎWear personal protective equipment.
Risk of injury due to incorrect handling of oxygen or cryogenic gases.
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 or 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 dan-
gers occurring in oxygen service and in applications with 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 department also offers
such training courses for service staff to allow them to learn how to handle devices for
the above listed applications correctly and safely.
Tip

EB 8093 EN 9
Safety instructions and measures
1.2 Notes on possible personal injury
WARNING
!
Crush hazard arising from moving parts.
The control valve contains moving parts (actuator and plug stems), which can injure
hands or ngers if inserted into the valve.
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.
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. cold burns.
ÎIf possible, drain the process medium from all the plant sections concerned and the
valve.
ÎWear protective clothing, safety gloves, and eyewear.

10 EB 8093 EN
Safety instructions and measures
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 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.
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. 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
corrode and damage the valve surface.
ÎOnly use lubricants approved by SAMSON (uAB0100).