Samson 3251 Service manual

Translation of original instructions
EB 8052-1 EN
Edition July 2020
Type3251 Valve for molten salt service · 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.
Definition 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 8052-1 EN

Contents
EB 8052-1 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 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 numbers........................................................................................2-2
2.4 Label when an adjustable packing is installed ...............................................2-2
3 Design and principle of operation ...............................................................3-1
3.1 Versions .....................................................................................................3-4
3.2 Additional ttings........................................................................................3-4
3.3 Valve accessories........................................................................................3-5
3.4 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.........................................................................................4-4
5 Installation.................................................................................................5-1
5.1 Installation conditions..................................................................................5-1
5.2 Preparation for installation...........................................................................5-3
5.3 Assembly ...................................................................................................5-3
5.3.1 Mounting the external anti-rotation xture.....................................................5-4
5.3.2 Mounting the actuator onto the valve..........................................................5-12
5.3.3 Installing the valve into the pipeline ............................................................5-13
5.4 Conguring the temperature control............................................................5-14
5.4.1 Determining the temperature limits .............................................................5-15
5.4.2 Calculating the required heating power ......................................................5-15
5.4.3 Conguring the temperature sensor ............................................................5-15
5.4.4 Conguring the electric trace heating..........................................................5-15
5.5 Testing the installed valve...........................................................................5-15
5.5.1 Leak test...................................................................................................5-17
5.5.2 Travel motion............................................................................................5-17

Contents
EB 8052-1 EN
5.5.3 Fail-safe position.......................................................................................5-18
5.5.4 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....................................................................................................9-1
9.1 Periodic testing ...........................................................................................9-3
9.2 Preparing the valve for service work .............................................................9-7
9.3 Mounting the valve after service work...........................................................9-7
9.4 Service work...............................................................................................9-8
9.4.1 Replacing the gasket ...................................................................................9-8
9.4.2 Replacing the packing.................................................................................9-9
9.4.3 Replacing the seat and plug.......................................................................9-10
9.5 Cleaning the pipelines...............................................................................9-11
9.6 Ordering spare parts and operating supplies ..............................................9-12
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
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

EB 8052-1 EN 1-1
Safety instructions and measures
1 Safety instructions and measures
Intended use
The SAMSON Type3251 Globe Valve in combination with an actuator (e.g. Type3271 or
Type3277 Pneumatic Actuator) is designed to regulate the ow rate of molten salt. 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
device 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.
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.
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 8052-1 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. 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.
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 8052-1 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 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 8052-1 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
Type3271 or Type3277 Pneumatic Actuator
−Mounting and operating instructions for mounted valve accessories (temperature sensor,
positioner, solenoid valve etc.)
−Documentation for devices by other manufacturers (e.g. for electric trace heating)
−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
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 burn injuries due to hot components and pipelines.
Components and pipelines reach temperatures above 300°C (570°F) while the plant is
running. Risk of severe burn injuries if touched.
ÎPrior to performing any work on the valve, allow components and pipelines to cool
down.
ÎWear protective clothing and safety gloves.

EB 8052-1 EN 1-5
Safety instructions and measures
Risk of burn injuries from molten salt.
Molten salt reaches very high temperatures of over 200°C (392°F) and leads to severe
burn injuries if touched.
ÎDo not touch molten salt.
ÎWear protective clothing and safety gloves when handling molten salt.
Risk of fatal injury due to electric shock.
The following applies when using electric trace heating or other electric components to
heat the valve components:
ÎOnly allow properly trained and instructed operating personnel to perform work on
the mounted device.
ÎObserve the safety instructions in the associated documentation.
1.2 Notes on possible personal injury
WARNING
!
Fire risk due to molten salt.
Individual elements in molten salt (both in crystallized and liqueed state) can acceler-
ate combustion or ignite on coming into contact with certain substances (e.g. graphite).
ÎDo not allow molten salt to come into contact with ammable substances.
Risk of poisoning from molten salt vapors.
Molten salt in the liqueed state produces vapors that are toxic.
ÎDo not inhale molten salt vapors.
ÎMake sure the area is sufciently ventilated.
ÎWear a respirator.
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.

1-6 EB 8052-1 EN
Safety instructions and measures
WARNING
!
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.
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).