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).

EB 8093 EN 11
Safety instructions and measures

12 EB 8093 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
1…5 9
SAMSON
20
Fig.1: Valve nameplate
1…5 PED (Pressure Equipment Directive), "Art. 4, Abs. 3"
ID of the notied body, uid group, and category
6Type designation
8 Material
9Year of manufacture
10 Valve size:
DIN: DN · ANSI: NPS
11 Pressure rating:
DIN: PN · ANSI: CL
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
15 Characteristic:
%: equal percentage · Lin: linear
16 Seat-plug seal:
ME: metal (see section3.3)
ST: Stellite®facing
PT: soft seal with PTFE
17 Seat code (trim material) · On request
20 Country of origin

EB 8093 EN 13
Markings on the control valve
The nameplate is afxed to the valve bonnet
(see Fig.2).
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 on nameplate). For more details on the
nameplate, see section2.1.
2 Valve bonnet
80 Nameplate
80
2
Fig.2: Nameplate on the valve bonnet

14 EB 8093 EN
Design and principle of operation
3 Design and principle of oper-
ation
The Type3248 is available in the following
versions:
−Globe valve with stainless steel body,
DN25 to 150, PN16 to 100 (see Fig.3)
−Angle valve with stainless steel body,
DN25 to 150, PN40 to 100 (see Fig.4)
−Angle valve with aluminum body, DN25
to 150, PN16 to 40 (see Fig.5)
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 servicing 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.
In the version with stainless steel body, the
cryogenic extension bonnet is welded onto
the body (1). Its bottom part consists of the
bellows seal and insulated pipe. In the ver-
sion with aluminum body, the bellows seal
(22) is screwed to the body. A cover plate
can be welded at a specic angle onto the
pipe or bellows seal. The cover plate serves
as orientation 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 PN16 to 40 version, the valve bonnet
(2) is designed as a yoke (see Fig.3). In the
PN63 and 100 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.4).
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. 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.
Actuators
The Type3248 Valve is preferably combined
with a SAMSON Type3271 or Type3277
Pneumatic Actuator (see Fig.3). It can also
be combined with other actuators.
The springs in the pneumatic actuator 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

EB 8093 EN 15
Design and principle of operation
Fig.3: Type3248 Globe Valve with
stainless steel body (PN16 to 40)
and with Type3271 Pneumatic
Actuator
Cover plate
1 Body (including cryogenic
extension bonnet)
2 Valve bonnet
4 Seat
5 Plug (with plug stem)
8 Threaded bushing (packing nut)
9 Stem 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

16 EB 8093 EN
Design and principle of operation
1
4
5
37
41
42
33
15
8
10
9
71
92
32
2
3
22
14
13
1
Fig.4: Type3248 Angle Valve with stainless steel
body (PN100)
Fig.5: Type3248 Angle Valve with aluminum
body (PN16 to 40)

EB 8093 EN 17
Design and principle of operation
plug to move. The actuator size is deter-
mined by the diaphragm area.
3.1 Fail-safe positions
The fail-safe position depends on the mount-
ed actuator.
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.
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
Larger nominal sizes
The Type3248 Valve is available up to nom-
inal size DN200.
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.
Tip
1 Body
2 Valve bonnet
3Yoke
4 Seat
5 Plug (with plug stem)
8 Threaded bushing (packing
nut)
9 Stem connector nut
10 Lock nut
13 Stud bolt
14 Body nut
15 Packing
17 Bonnet gasket
22 Bellows seal
32 Bolt
33 Nut
37 Plug stem with metal bellows
41 Bellows nut
42 Test connection
71 Spacer stem
92 Castellated nut

18 EB 8093 EN
Design and principle of operation
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.
3.3 Technical data
The nameplates on the valve and actuator
provide information on the control valve
version. See section2.1 and the actuator
documentation.
More information is available in Data Sheet
uT8093.
Compliance
The Type3248 Valve bears both the CE and
EAC marks of conformity.
Temperature range
The Type3248 Valve is designed for a
temperature range from –196 to +65°C.
The use of an extended bellows seal extends
the temperature range down to –273°C.
Leakage class
Depending on the version, the following
leakage class according to IEC60534-4
applies:
Seal (16 on nameplate) Leakage class
Metal seal (ME) IV
High-performance metal
seal, e.g. Stellite®facing
(ST)
V
PTFE soft seal (PT) VI
Noise emission
SAMSON is unable to make general
statements about noise emission as it
depends on the valve version, plant facilities,
and process medium. On request, SAMSON
can perform calculations according to
IEC60534, Part8-3 and Part8-4 or
VDMA24422 (edition 89).
Risk of hearing loss or deafness due to loud
noise.
Wear hearing protection when working near
the valve.
Dimensions and weights
Table1 to Table5 provide a summary of the
dimensions of the various versions of
Type3248 Valve. Table6 lists the weights of
the various versions of Type3248 Valve. The
lengths and heights in the dimension dia-
grams are shown on page22.
Note
Note
WARNING
!

EB 8093 EN 19
Design and principle of operation
Height H7 is the minimum clearance for ser-
vice work. The actuator dimensions must also
be observed. The largest value applies.
Height H1 and the specied weights are ref-
erence values. The exact dimensions and
weights depend on various factors, e.g. ac-
tuator size and overall height.
Note
Table1: Dimensions of globe valve with stainless steel body, PN16 to 40
Valve DN 25 40 50 80 100 150
Lmm 210 251 286 337 394 508
H1 mm 854 864 864 1052 1147.5 1188.5
H2 mm 44 71 71 93 111 174
H4 mm 600 600 600 700 800 800
H5 mm 708 714 714 824 933.5 974.5
H7 mm 1050 900 900 900 1100 1100
Ød mm 282 282 282 282 282 282
Welding ends/
pipe connection1)
Ø33.7
x 2.3
Ø48.3
x2.6
Ø60.3
x 3.2
Ø88.9
x 4
Ø114.3
x 5
Ø168.3
x 5.6
1) Deviating dimensions on request

20 EB 8093 EN
Design and principle of operation
Table2: Dimensions of globe valve with stainless steel body, PN63 and 100
Valve DN 25 40 50 80 100 150
Lmm 210 251 286 337 394 508
H11) mm 822 817 817 832 984 1298
H2 mm 44 71 71 93 111 174
H42) mm 600 600 600 600 650 800
H5 mm 734 734 734 734 786 923
H7 mm 1050 900 900 900 1100 1100
Ød mm 282 282 282 282 282 282
Welding ends/
pipe connection2)
Ø33.7
x 3.2
Ø48.3
x 3.6
Ø60.3
x 4
Ø88.9
x 5.6
Ø114.3
x 6.3
Ø168.3
x 7.1
1) Dimension H1+85mm applies when 1400-120cm² actuators are used
2) Deviating dimensions on request
Table3: Dimensions of angle valve with stainless steel body, PN40
Valve DN 25 40 50 80 100 150
Lmm 98 133 133 159 184 236
H1 mm 830 845 845 1017 1108 1101
H4 mm 600 600 600 650 750 750
H5 mm 684 695 695 788 893 887
H7 mm 1050 900 900 900 1100 1100
Ød mm 282 282 282 282 282 282
Welding ends/
pipe connection
Ø33.7
x 2.3
Ø48.3
x 2.6
Ø60.3
x 3.2
Ø88.9
x 4
Ø114.3
x 5
Ø168.3
x 5.6