Samson 3251 Service manual

Translation of original instructions
EB 8052-1 EN
Type3251 Valve for molten salt service · ANSI version
In combination with an actuator,
e.g. a SAMSON Type3271 or Type3277 Pneumatic Actuator
Edition August 2016

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
at www.samson.de > 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
2 EB 8052-1 EN

Contents
EB 8052-1 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 ........................................................................................14
3.2 Versions ......................................................................................................16
3.3 Technical data .............................................................................................17
4 Measures for preparation............................................................................24
4.1 Unpacking ..................................................................................................24
4.2 Transporting and lifting ................................................................................24
4.2.1 Transporting ................................................................................................25
4.2.2 Lifting..........................................................................................................25
4.3 Storage.......................................................................................................28
4.4 Preparation for installation............................................................................29
5 Mounting and start-up.................................................................................30
5.1 Mounting the actuator onto the valve.............................................................30
5.2 Installing the valve into the pipeline ...............................................................31
5.2.1 Checking the installation conditions...............................................................31
5.2.2 Additional ttings.........................................................................................33
5.2.3 Installing the control valve.............................................................................34
5.3 Conguring the temperature control...............................................................34
5.3.1 Determining the temperature limits ................................................................35
5.3.2 Calculating the required heating power .........................................................35
5.3.3 Conguring the temperature sensor ...............................................................35
5.3.4 Conguring the electric trace heating.............................................................35
5.4 Quick check ................................................................................................36

Contents
4 EB 8052-1 EN
6 Operation...................................................................................................38
6.1 Working in manual mode.............................................................................39
7 Servicing.....................................................................................................40
7.1 Inspection intervals.......................................................................................41
7.2 Replacing the gasket ....................................................................................43
7.2.1 Standard version..........................................................................................43
7.2.2 Version with bellows seal..............................................................................43
7.3 Replacing the packing..................................................................................45
7.4 Replacing the seat and plug..........................................................................47
7.5 Cleaning the pipelines..................................................................................48
7.6 Preparation for return shipment.....................................................................49
7.7 Ordering spare parts and operating supplies .................................................49
8 Malfunctions ...............................................................................................50
8.1 Troubleshooting ...........................................................................................50
8.2 Emergency action ........................................................................................51
9 Decommissioning and disassembly ..............................................................52
9.1 Decommissioning.........................................................................................53
9.2 Removing the valve from the pipeline.............................................................53
9.3 Removing the actuator from the valve ............................................................54
9.4 Disposal......................................................................................................54
10 Appendix....................................................................................................54
10.1 After-sales service........................................................................................54
10.2 Certicates ..................................................................................................54
10.3 Spare parts .................................................................................................56

EB 8052-1 EN 5
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 pres-
sure, process medium, temperature). Therefore, operators must ensure that the control valve is
only used in applications 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. 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.

6 EB 8052-1 EN
Safety instructions and measures
Personal protective equipment
We recommend wearing the following protective equipment when handling molten salt:
−Wear protective clothing, in particular safety gloves, a respirator, and eyewear.
−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 devices
Upon supply air or control signal failure, the valve moves to its fail-safe position (see sec-
tion3.1). The fail-safe action corresponds with the direction of action. The fail-safe action of
SAMSON actuators is specied on the actuator nameplate (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, operators 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 8052-1 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
SAMSON Type3271 and Type3277 Actuators
−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WA0029 for tools and tightening torques

8 EB 8052-1 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 and from the valve.
ÎWear personal protective equipment.
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.
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 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.

EB 8052-1 EN 9
Safety instructions and measures
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.
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 nger 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).

10 EB 8052-1 EN
Safety instructions and measures
WARNING
!
Risk of personal injury due to residual process medium in the valve.
While working on the valve, residual process medium can escape and may lead to per-
sonal injury, e.g. burns.
ÎIf possible, drain the process medium from all the plant sections concerned and from
the valve.
ÎWear protective clothing, safety gloves, and eyewear.
1.3 Notes on possible property damage
NOTICE
!
Risk of damage to the valve and pipelines due to the process medium crystallizing.
The molten salt crystallizes when its temperature falls below the salt's melting point. The
crystallized medium accumulates in the valve and pipelines causing them to become
blocked. The bellows seal is damaged as a result.
ÎObserve the temperature limits of the process medium. See section5.3.1.
ÎOnly stroke the valve with bellows seal when the process medium is in the liqueed
state.
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 leakage and valve damage due to excessively high or low tightening torques.
Observe the specied torques on tightening control valve components. Excessively tight-
ened torques lead to parts wearing out quicker. Parts that are too loose may cause leak-
age.
ÎObserve the specied tightening torques (uWA0029).

EB 8052-1 EN 11
Safety instructions and measures
NOTICE
!
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WA0029).
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 the valve surface.
ÎOnly use lubricants approved by SAMSON (see parts list).

12 EB 8052-1 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
19
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
9 Year of manufacture
10 Valve size:
DIN: DN · ANSI: NPS· JIS: DN…A/B
11 Pressure rating:
DIN: PN · ANSI: CL · JIS: K
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 · JIS: CV
15 Characteristic:
%: equal percentage · Lin: linear · NO/NC: quick opening
16 Seat/plug seal:
ME: metal (see section3.3)
ST: Stellite®facing
17 Seat code (trim material) · On request
19 Flow divider:
1: ST11)
20 Country of origin
1) As special version for gas

EB 8052-1 EN 13
Markings on the control valve
The nameplate (80) is afxed to the yoke of
the valve (see Fig.2).
80
80
Fig.2: Nameplate position
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). For more details on the nameplate, see
section2.1.

14 EB 8052-1 EN
Design and principle of operation
3 Design and principle of oper-
ation
The single-seated Type3251 Globe 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 body (1) is designed either with anges
or welding ends (optionally with additional
welding-neck ends). The seat (4) and plug
(5) are installed in the body. The plug stem is
connected to the actuator stem (A7) by stem
connector clamps (A26) and sealed by an
adjustable packing (15). This packing
(FormMS) is specially designed for molten
salt service and has an additional zinc-im-
pregnated coating to protect against corro-
sion and prevent leakage. The valve can be
tted with a bellows seal (22) to allow it to
withstand high temperatures up to 580°C.
In this version, a test connection (42) on the
bonnet (2) allows leakage monitoring.
The springs (A10) in the pneumatic actuator
are located either above or below the dia-
phragm (A4) depending on the selected fail-
safe action (see section3.1). A change in
the signal pressure acting on the diaphragm
causes the plug to move. The actuator size is
determined by the diaphragm area.
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.
Molten salt
Molten salt is used in heat recovery plants
instead of organic heat transfer oils. Molten
salt remains liqueed at temperatures up to
almost 600°C. It is neither ammable nor
toxic. It has a higher heat capacity than con-
ventional heat transfer media.
An exact temperature control and monitoring
of molten salt is essential since it solidies
very quickly as it cools down. For this pur-
pose, the bonnet (2) of the valve is designed
with a connection for a temperature sensor.
3.1 Fail-safe positions
The fail-safe position depends on the actua-
tor used.
1 Body
2 Bonnet
3Yoke
4Seat
5 Plug
8 Threaded bushing
(packing nut)
9 Stem connector nut
10 Lock nut
14 Body nut
15 Packing
17 Body gasket
22 Bellows seal
37 Plug stem with bellows
42 Test connection
84 Travel indicator scale
92 Castellated nut
A4 Diaphragm
A7 Actuator stem
A8 Ring nut
A10 Spring
A16 Vent plug
A26 Stem connector clamps
S Signal pressure connection

EB 8052-1 EN 15
Design and principle of operation
9
10
8
92
3
2
5
4
15
14
17
1
4
5
2
92
8
10
9
1
17
14
3
A16
A10
A4
S
A7
84
A26
A8
22
37
15
42
Connection for
temperature sensor
Fig.3: Type3251 Valve for molten salt service: with welding ends, bellows seal, and Type3271
Pneumatic Actuator (left) · Standard version with anges (right)

16 EB 8052-1 EN
Design and principle of operation
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
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
Table1: Technical data
Type3251 Valve for molten salt service
Material Body A351CF8C
Process medium Molten salt
Minimum
temperature
Process medium Depending on the melting point
Valve components 50°C above melting point
Temperature range Standard version –10 to +400°C (14 to 752°F)
With bellows seal –10 to +580°C (14 to +1076°F)
Leakage class According to ANSI/
FCI70-2 IV
Compliance ·

EB 8052-1 EN 17
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 an actuator with additional hand-
wheel, an electric actuator or a pneumatic
piston actuator.
3.3 Technical data
The nameplates on the valve and actuator
provide information on the control valve ver-
sion. See section2.1 and the associated ac-
tuator documentation.
An excerpt of the technical data is listed in
Table1.
More information is available in Data Sheet
uT8052.
Noise emission
SAMSON is unable to make general state-
ments about noise emission as it depends on
the valve version, plant facilities, and pro-
cess medium.
Risk of hearing loss or deafness due to loud
noise.
Wear hearing protection when working near
the valve.
Note
Note
WARNING
!

18 EB 8052-1 EN
Design and principle of operation
Dimensions and weights
Table2 to Table5 provide a summary of the dimensions and weights of the standard version
of Type3251 Valve. Table6 to Table9 provide a summary of the dimensions and weights of
the Type3251 Valve with bellows seal. The lengths and heights are dened in the dimension
diagrams on p.19 and are based on a valve combined with a SAMSON Type3271 or
Type3277 Actuator.
Table2: Dimensions of Type3251 Valve, up to NPS6
Valve NPS ½ 1 1½ 2 34 6
DN 15 25 40 50 80 100 150
Length L
(anges RF
and weld-
ing ends)
Class 150 in 7.25 7.25 8.75 10.00 11.75 13.88 17.75
mm 184 184 222 254 298 352 451
Class 300 in 7.50 7.75 9.25 10.50 12.50 14.50 18.62
mm 190 197 235 267 318 368 473
Class 600 in 8.00 8.25 9.88 11.25 13.25 15.50 20.00
mm 203 210 251 286 337 394 508
Class 900 in 8.50 10.00 12.00 14.50 15.00 18.00 24.00
mm 216 254 305 368 381 457 610
Height H4
Class 150
to 600
in 5.98 5.98 6.46 8.54 8.74 9.53 12.36
mm 152 152 164 217 222 242 314
Class 900 in 7.32 7.32 7.68 9.88 8.74 9.53 12.36
mm 186 186 195 251 222 242 314
H8 for
actuator
350cm² in 9.45 9.45 9.45 9.45 9.45 9.45 –
mm 240 240 240 240 240 240
355cm² in 9.45 9.45 9.45 9.45 9.45 9.45 16.46
mm 240 240 240 240 240 240 418
700cm² in 9.45 9.45 9.45 9.45 9.45 9.45 16.46
mm 240 240 240 240 240 240 418
750cm² in 9.45 9.45 9.45 9.45 9.45 9.45 16.46
mm 240 240 240 240 240 240 418

EB 8052-1 EN 19
Design and principle of operation
Valve NPS ½ 1 1½ 2 34 6
DN 15 25 40 50 80 100 150
H8 for
actuator
1000cm² in
–
11.61 11.61 11.61 16.46
mm 295 295 295 418
1400-
60cm²
in 11.61 11.61 11.61 16.46
mm 295 295 295 418
1400-
120cm²
in 18.90 18.90 18.90 19.80
mm 480 480 480 503
2800cm² in 18.90 18.90 18.90 19.80
mm 480 480 480 503
2x2800cm² in 18.90 18.90 18.90 19.80
mm 480 480 480 503
H2 (NPS4
and larger
with foot)
Class 150 in 1.97 2.36 3.05 3.54 3.94 6.3 8.66
mm 50 60 80 90 100 160 220
Class 300
to 600
in 2.36 2.76 3.54 3.94 4.72 7.09 9.25
mm 60 70 90 100 120 180 235
Class 900 in 2.76 3.05 3.94 4.33 4.72 7.09 9.25
mm 70 80 100 110 120 180 235
Dimensional drawings
H2
L
H4 H8
H4 H8
L
H2
L
H4 H8
Type3251 up to NPS3 without
foot
Type3251 in NPS4 and larger
with foot
Type3251 Valve with bellows
seal and welding ends

20 EB 8052-1 EN
Design and principle of operation
Table3: Dimensions of Type3251 Valve, NPS8 and larger
Valve NPS 8 10 12 14 16 20
DN 200 250 300 – 400 500
Length L
(anges RF
and welding
ends)
Class 150 in 21.38 26.50 29.00 35.00 40.00 On request
mm 543 673 737 889 1016
Class 300 in 22.38 27.88 30.50 36.50 41.62 On request
mm 568 708 775 927 1057
Class 600 in 24.00 29.62 32.25 38.25 43.62 On request
mm 610 752 819 972 1108
Class 900 in 29.00 33.00 38.00 40.50 On request
mm 737 838 965 1029
Height H4
Class 150
to 600
in 15.24 17.401) 25.79 25.20 25.20 On request
mm 387 4421) 655 640 640
Class 900 in 15.24 20.432) 25.79 On request
mm 387 5192) 655
H8 for
actuator
350cm² in –
mm
355cm² in –
mm
700cm² in 16.46 16.46 –
mm 418 418
750cm² in 16.46 16.46 –
mm 418 418
H8 for
actuator
1000cm² in 16.46 On request
mm 418
1400-
60cm²
in 16.46 On request
mm 418
1400-
120cm²
in 19.80 19.80 25.59 25.59 25.59 25.59
mm 503 5033) 650 650 650 650
2800cm² in 19.80 19.80 25.59 25.59 25.59 25.59
mm 503 5033) 650 650 650 650
2x2800cm² in 19.80 19.80 25.59 25.59 25.59 25.59
mm 503 5033) 650 650 650 650