Samson 3251-E Service manual

Translation of original instructions
EB 8052-E EN
Edition January 2021
Type3251-E Valve · ANSI version
In combination with an actuator,
e.g. a Type3271 or Type3277 Pneumatic Actuator
Type3251-E Valve with 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 8052-E EN

Contents
EB 8052-E EN
1 Safety instructions and measures ................................................................1-1
1.1 Notes on possible severe personal injury ......................................................1-4
1.2 Notes on possible personal injury ................................................................1-5
1.3 Notes on possible property damage.............................................................1-7
1.4 Notes on the use of an RFID tag ...................................................................1-8
1.5 Warnings on the device...............................................................................1-8
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
2.4 Label when an adjustable packing is installed ...............................................2-2
2.5 Optional RFID tag.......................................................................................2-2
3 Design and principle of operation ...............................................................3-1
3.1 Fail-safe action ...........................................................................................3-1
3.2 Versions .....................................................................................................3-5
3.3 Accessories ................................................................................................3-5
3.4 Additional ttings........................................................................................3-5
3.5 Valve accessories........................................................................................3-6
3.6 Technical data ............................................................................................3-6
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.........................................................................................4-4
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 Mounting the external anti-rotation xture.....................................................5-4
a) Standard version for valve size NPS6 and larger..........................................5-4
b) Special version for valve sizes NPS3 to 4.....................................................5-7
5.3.2 Mounting the actuator onto the valve..........................................................5-13
5.3.3 Installing the valve into the pipeline ............................................................5-14
5.4 Testing the installed valve...........................................................................5-15

Contents
EB 8052-E EN
5.4.1 Leak test...................................................................................................5-16
5.4.2 Travel motion............................................................................................5-18
5.4.3 Fail-safe position.......................................................................................5-18
5.4.4 Pressure test..............................................................................................5-18
6 Start-up .....................................................................................................6-1
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 and conversion............................................................................9-1
9.1 Periodic testing ...........................................................................................9-3
9.2 Preparation for servicing or conversion work.................................................9-5
9.3 Mounting the actuator on the valve after service or conversion work ...............9-6
9.4 Service or conversion work........................................................................9-10
9.4.1 Replacing the gaskets ................................................................................9-10
a) Version with clamped-in seat and plug .......................................................9-10
b) Version with screwed-in seat and plug........................................................9-11
c) Version with cage and piston .....................................................................9-13
9.4.2 Replacing the packing...............................................................................9-13
a) Standard and HT packing..........................................................................9-13
b) LLF20 packing .........................................................................................9-15
9.4.3 Replacing the trim.....................................................................................9-18
a) Removing the (clamped-in) seat and plug....................................................9-18
b) Removing the (screwed-in) seat and plug ....................................................9-19
c) Removing the cage and piston ...................................................................9-21
d) Installing the (clamped-in) seat and plug.....................................................9-22
e) Installing the (screwed-in) seat and plug......................................................9-23
f) Installing the cage and piston.....................................................................9-25
9.5 Ordering spare parts and operating supplies ..............................................9-27
10 Decommissioning .....................................................................................10-1
11 Removal ..................................................................................................11-1
11.1 Removing the valve from the pipeline..........................................................11-2
11.2 Removing the actuator from the valve .........................................................11-2

Contents
EB 8052-E EN
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.....................................................................................15-3

Contents
EB 8052-E EN

EB 8052-E EN 1-1
Safety instructions and measures
1 Safety instructions and measures
Intended use
The SAMSON Type3251-E 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,
operators must ensure that the control valve is only used in operating 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.
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.

1-2 EB 8052-E EN
Safety instructions and measures
Personal protective equipment
We recommend checking the hazards posed by the process medium being used (e.g.
uGESTIS (CLP) hazardous substances database). 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.
Furthermore, 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.
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.

EB 8052-E EN 1-3
Safety instructions and measures
Responsibilities of the operator
Operators are responsible for proper use 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, 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 8052-E EN
Safety instructions and measures
1.1 Notes on possible severe personal injury
DANGER
!
Risk of bursting in pressure equipment.
Valves and pipelines are pressure equipment. 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.
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
− Manual uH02: Appropriate Machinery Components for SAMSON Pneumatic Control
Valves with a Declaration of Conformity of Final Machinery
− When a substance is used in the device, which is listed as being a substance of very high
concern on the candidate list of the REACH regulation:
Information on safe use of the part affected
uwww.samsongroup.com > About SAMSON > Material Compliance > REACH
If a device contains a substance which is listed as being a substance of very high concern
on the candidate list of the REACH regulation, this circumstance is indicated on the
SAMSON delivery note.

EB 8052-E EN 1-5
Safety instructions and measures
1.2 Notes on possible personal injury
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 warm up to the ambient tempera-
ture.
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 or piston 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 or piston stem by inserting
objects into the yoke.
ÎBefore unblocking the actuator and plug or piston 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 asso-
ciated actuator documentation.

1-6 EB 8052-E EN
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.

EB 8052-E EN 1-7
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.

1-8 EB 8052-E EN
Safety instructions and measures
1.5 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 or piston
stem if they are inserted into the yoke while the air
supply is connected to the actuator.
1.4 Notes on the use of an RFID tag
The RFID tag is subject to certain restrictions due to its application range (technical specica-
tions).
ÎObserve the explosion protection certicates of the RFID tag when it is to be used on
valves installed in potentially explosive atmospheres.
ÎDo not expose the RFID tag to strong electric elds.
ÎAvoid electrostatic charging.
ÎObserve the application range (technical specications) of the RFID tag.

EB 8052-E 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3251-E Valve actually appear on the
nameplate.
Note
Item Inscription meaning
1Data 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: perforated plug with ow divider ST1
to ST3 · MHC1:multi-hole cage
LDB:cage with noise attenuation
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 8052-E EN
Markings on the device
The nameplate (80) is afxed to the yoke of
the valve (see Fig.2-2).
80
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.
2.4 Label when an adjustable
packing is installed
An instructional label is afxed to the valve
when an adjustable packing is installed (see
Fig.2-3).
Fig.2-3: Label when an adjustable packing is
installed
2.5 Optional RFID tag
The RFID tag is located directly next to the
nameplate on valves ordered with the RFID
tag option. It contains the same data as in-
cluded in the Data Matrix code on the elec-
tronic nameplate. It can be read using a
smartphone, tablet or RFID reader.
Application range according to the technical
data (see the ‘Design and principle of opera-
tion’ section).

EB 8052-E EN 3-1
Design and principle of operation
3 Design and principle of oper-
ation
The Type3251-E Valve is a single-seated
globe valve. This valve is preferably com-
bined with a SAMSON Type3271 or
Type3277 Pneumatic Actuator. It can also
be combined with other actuators.
The body can be tted with three different
trims:
− With clamped-in seat and plug (see
Fig.3-1)
− With screwed-in seat and plug (see
Fig.3-2)
− With piston and cage trim (see Fig.3-3)
All the trims are interchangeable in the eld
without any revisions necessary to the pres-
sure-bearing or pressure-retaining parts.
The plug or piston stem (5.1) is connected to
the actuator stem (A7) by the stem connector
clamps (A26/A27) and sealed by a
spring-loaded V-ring packing (15) or a
cord-ring packing (15). The springs (A10) in
the pneumatic actuator are located either
above or below the diaphragm (A4) de-
pending on the selected fail-safe action. A
change in the signal pressure acting on the
diaphragm causes the plug (5) or piston (5)
to move. The actuator size is determined 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 po-
sition of the plug (5) in the seat (4) or the po-
sition of the piston (5) in the cage (124)
changes and determines the ow rate
through the valve.
We recommend the use of positioners with
integrated diagnostic rmware (see
section3.5) for valves used for on/off
service. The partial stroke test included in this
software helps prevent a shut-off valve
normally in its end position from seizing up
or getting jammed.
3.1 Fail-safe action
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 (A10) move the
actuator stem (A7) downward and close the
valve. The valve opens when the signal pres-
sure is increased enough to overcome the
force exerted by the springs.
Tip

3-2 EB 8052-E EN
Design and principle of operation
1 Body
2Valve bonnet
4 Clamped-in seat
5 Plug
5.1 Plug stem
7 Guide bushing
8 Packing follower
9Stem connector nut
10 Lock nut
13 Stud
14 Hex nut
15 Packing
17 Spiral gasket
60 Yoke
92 Castellated nut
124 Seat retainer
126 Spiral gasket
127 Spiral gasket
162 Packing gland
163 Spring loading
assembly (packing)
164 Stud for packing
gland
A4 Actuator diaphragm
A7 Actuator stem
A8 Ring nut
A10 Actuator springs
A26/
A27
Stem connector
clamps
SSignal pressure
connection
4
1
127
5
7
124
126
17
2
14
13
15
92
8
5.1
60
10
9
164
163
162
S
A26/A27
A7
A8
A4
A10
Fig.3-1: Type3251-E Valve with clamped-in seat and Type3277 Pneumatic Actuator

EB 8052-E EN 3-3
Design and principle of operation
1 Body
2Valve bonnet
4 Screwed-in seat
5 Plug
5.1 Plug stem
7 Guide bushing
8 Packing follower
9Stem connector nut
10 Lock nut
13 Stud
14 Hex nut
15 Packing
17 Spiral gasket
60 Yoke
92 Castellated nut
127 Spiral gasket
162 Packing gland
163 Spring loading
assembly (packing)
164 Stud for packing
gland
221 Seat ring
A4 Actuator diaphragm
A7 Actuator stem
A8 Ring nut
A10 Actuator springs
A26/
A27
Stem connector
clamps
SSignal pressure
connection
4
1
127
221
5
7
17
2
5.1
14
13
15
92
8
60
10
9
164
163
162
S
A26/A27
A7
A8
A4
A10
Fig.3-2: Type3251-E Valve with screwed-in seat and Type3271 Pneumatic Actuator

3-4 EB 8052-E EN
Design and principle of operation
1 Body
2Valve bonnet
4 Cage seat
5 Piston
5.1 Piston stem
8 Packing follower
9Stem connector nut
10 Lock nut
13 Stud
14 Hex nut
15 Packing
17 Spiral gasket
45 Gasket
60 Yoke
63 Cylinder
92 Castellated nut
124 Cage
126 Spiral gasket
127 Spiral gasket
162 Packing gland
163 Spring loading
assembly (packing)
164 Stud for packing
gland
A4 Actuator diaphragm
A7 Actuator stem
A8 Ring nut
A10 Actuator springs
A26/
A27
Stem connector
clamps
SSignal pressure
connection
4
1
127
5
124
126
17
2
14
13
15
92
8
5.1
60
10
9
164
163
162
S
A26/A27
A7
A8
A4
A10
45
63
Fig.3-3: Type3251-E Valve with cage trim and Type3271 Pneumatic Actuator