Samson 3259 Setup guide

Translation of original instructions
EB 8059 EN
Edition December 2017
Type 3259 Valve
In combination with an actuator,
e.g. a SAMSON 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.
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 8059 EN

Contents
EB 8059 EN 3
1 Safety instructions and measures ...................................................................5
1.1 Notes on possible severe personal injury .........................................................8
1.2 Notes on possible personal injury ...................................................................8
1.3 Notes on possible property damage................................................................9
2 Markings on the device ...............................................................................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 .............................................................................................16
4 Measures for preparation............................................................................20
4.1 Unpacking ..................................................................................................20
4.2 Transporting and lifting ................................................................................20
4.2.1 Transporting ................................................................................................21
4.2.2 Lifting..........................................................................................................22
4.3 Storage.......................................................................................................25
4.4 Preparation for installation............................................................................25
5 Mounting and start-up.................................................................................27
5.1 Mounting the actuator onto the valve.............................................................27
5.2 Installing the valve into the pipeline ...............................................................28
5.2.1 Checking the installation conditions...............................................................28
5.2.2 Additional ttings.........................................................................................29
5.2.3 Installing the control valve.............................................................................29
5.3 Quick check ................................................................................................30
6 Operation...................................................................................................32
6.1 Working in manual mode.............................................................................32

Contents
4 EB 8059 EN
7 Servicing.....................................................................................................34
7.1 Preparing the valve for servicing ...................................................................35
7.2 Replacing the body gasket............................................................................35
7.2.1 Standard version..........................................................................................35
7.2.2 Version with insulating section.......................................................................37
7.2.3 Version with bellows seal..............................................................................37
7.3 Replacing the packing..................................................................................38
7.3.1 Standard version..........................................................................................38
7.3.2 Version with insulating section.......................................................................40
7.4 Replacing the seat and plug..........................................................................41
7.4.1 Standard version..........................................................................................41
7.4.2 Version with insulating section.......................................................................43
7.5 Preparation for return shipment.....................................................................44
7.6 Ordering spare parts and operating supplies .................................................44
8 Malfunctions ...............................................................................................46
8.1 Troubleshooting ...........................................................................................46
8.2 Emergency action ........................................................................................47
9 Decommissioning and disassembly ..............................................................48
9.1 Decommissioning.........................................................................................48
9.2 Removing the valve from the pipeline.............................................................48
9.3 Removing the actuator from the valve ............................................................48
9.4 Disposal......................................................................................................48
10 Annex.........................................................................................................49
10.1 After-sales service........................................................................................49
10.2 Certicates ..................................................................................................49
10.3 Spare parts .................................................................................................52

EB 8059 EN 5
Safety instructions and measures
1 Safety instructions and measures
Intended use
The SAMSON Type3259 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, gases or vapors in industrial high-pressure plants according to the IG standard.
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 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 8059 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 substance database).
ÎProvide protective equipment (e.g. safety gloves, eye protection) appropriate for the pro-
cess medium used.
ÎWear 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 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 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 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.
We also recommend checking the hazards posed by the process medium being used (e.g.
uGESTIS (CLP) hazardous substance database).
ÎObserve safety measures for handling the device as well as re prevention and explosion
protection measures.
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.

EB 8059 EN 7
Safety instructions and measures
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, the 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. Valves with a CE marking have an EU declaration of conformity, which
includes information about the applied conformity assessment procedure. This EU 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

8 EB 8059 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. Improper opening can lead to valve
components bursting.
ÎBefore starting any work on the 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.
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.

EB 8059 EN 9
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 process medium can escape and, depending on
its properties, may lead to personal injury, e.g. (chemical) burns.
ÎIf possible, drain the process medium from all the plant sections concerned and the
valve.
ÎWear protective clothing, safety gloves, and eyewear.
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 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.

10 EB 8059 EN
Safety instructions and measures
NOTICE
!
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 8059 EN 11

12 EB 8059 EN
Markings on the device
2 Markings on the device
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
6 Type 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
HA: carbide metal
ST: Stellite®facing
KE: ceramic
PT: soft seal with PTFE
PK: soft seal with PEEK
17 Seat code (trim material) · On request
20 Country of origin

EB 8059 EN 13
Markings on the device
The nameplate (80) is afxed to the yoke of
the valve (see Fig.2).
80
Fig.2: Valve nameplate
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.

14 EB 8059 EN
Design and principle of operation
3 Design and principle of oper-
ation
The Type3259 High-pressure Angle 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 seat (4) and plug with plug stem (5) are
installed in the body (1). The plug stem is
connected to the actuator stem (A7) by the
stem connector clamps (A26/27) and is
sealed by a spring-loaded double PTFE
packing (15). Alternatively, an adjustable
high-temperature packing can be used. The
springs in the pneumatic actuator are locat-
ed either above or below the diaphragm de-
pending 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.
3.1 Fail-safe positions
The fail-safe position depends on the mount-
ed actuator. Depending on how the com-
pression springs are arranged in the pneu-
matic 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.
1Body
2 Intermediate piece
4 Seat
5Plug
7 Guide bushing
8 Threaded bushing
(packing nut)
10 Lock nut
14 Body nut
15 Packing
17 Body gasket (lens ring
gasket)
56 Threaded ange
57 Threaded ange
60 Yoke assembly
92 Castellated nut
111 Threaded ange
A4 Diaphragm
A7 Actuator stem
A8 Ring nut
A10 Spring
A26/27 Stem connector clamp
S Signal pressure
connection

EB 8059 EN 15
Design and principle of operation
S
A26/27
17
A7
A8
A4
A10
56
7
5
1
4
14
2
15
60
92
8
10
57
111
S
Fig.3: Type3259 Valve with Type3271 Pneumatic Actuator (left) and Type3277 Pneumatic
Actuator (right)

16 EB 8059 EN
Design and principle of operation
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
Insulating section or bellows seal
The modular design allows an insulating sec-
tion or bellows seal to be tted to the stan-
dard valve version.
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.
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.
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 actuator docu-
mentation.
More information is available in Data Sheet
uT8059.
Noise emission
SAMSON is unable to make general
statements about noise emission as it
depends on the valve version, plant facilities
and process medium.
Risk of hearing loss or deafness due to loud
noise.
Wear hearing protection when working near
the valve.
Dimensions and weights
Table2 to Table4 contain the dimensions
and weights for Type3259. The lengths and
heights in the dimension diagrams are
shown on page19.
Dimensions in mm · Weights in kg
Tip
Note
Note
WARNING
!

EB 8059 EN 17
Design and principle of operation
Table1: Technical data
Valve size DN 16 · 24 · 30 · 45 · 58 · 70 · 90
Nominal pressure PN 325
Type of connection Threaded anges with lens ring gaskets according to the
IG standard
Seat-plug seal Metal seal or high-performance metal seal
Characteristic Equal percentage or linear
Rangeability 50:1 for KVS≥ 1 · 30:1 for KVS< 1
Compliance ·
Temperature ranges in °C · Permissible operating pressures according to pressure-temperature dia-
gram
Body without
insulating section
with
PTFE packing –10 to +220°C
High-temperature
packing –10 to +350°C
Body with Insulating section –10 to +450°C
Bellows seal –10 to +450°C
Leakage class according to IEC60534‑4
Valve plug Metal seal IV · High-performance metal seal: V
Table2: Dimensions and weights for standard version of Type3259 Valve
Valve size DN 16 24 30 45 58 70 90
Length L 95 110 120 150 170 200 235
H1 for
actuator
350cm² 470 470 470 560 560 –
355v2cm² 470 470 470 560 560 –
700cm² 470 470 470 560 560 820 820
750v2cm² 470 470 470 560 560 820 820
1000cm²
1400-60cm² 525 525 525 615 615 820 820
1400-120cm²
2800cm² – 800 800 905 905
2x2800cm² – 905 905
Weight without actuator 35 40 45 851) 901) 2201) 2301)
1) The weight of the valve with a 2800cm² or 2x 2800cm² actuator increases by 30kg.

18 EB 8059 EN
Design and principle of operation
Table3: Dimensions and weights for Type3259 with insulating section
Valve size DN 16 24 30 45 58 70 90
H4 for
actuator
350cm² 735 735 735 810 810 –
355v2cm² 735 735 735 810 810 –
700cm² 735 735 735 810 810 1175 1175
750v2cm² 735 735 735 810 810 1175 1175
1000cm²
1400-60cm² 790 790 790 865 865 1175 1175
1400-120cm²
2800cm² – 1050 1050 1260 1260
2x2800cm² – 1260 1260
Weight without actuator 45 48 53 1001) 1051) 2951) 3051)
1) The weight of the valve with a 2800cm² or 2x 2800cm² actuator increases by 30kg.
Table4: Dimensions and weights for Type3259 with bellows seal
Valve size DN 16 24 30 45 58 70 90
H4 for
actuator
350cm² 885 885 885 875 875 –
355v2cm² 885 885 885 875 875 –
700cm² 885 885 885 875 875 1485 1485
750v2cm² 885 885 885 875 875 1485 1485
1000cm²
1400-60cm² 940 940 940 930 930 1485 1485
1400-120cm²
2800cm² – 1115 1115 1570 1570
2x2800cm² – 1570 1570
Weight without actuator On request

EB 8059 EN 19
Design and principle of operation
Dimensional drawings
H1
L
L
H4L
L
H4
L
L
Standard version of Type3259 Type3259 with insulating
section
Type3259 with bellows seal
The associated actuator documentation applies to actuators, e.g. for SAMSON pneumatic
actuators:
uT8310‑1 for Type3271 and Type3277 Actuators up to 750v2cm² actuator area
uT8310‑2 for Type3271 Actuator with 1000cm² actuator area and larger
uT8310‑3 for Type3271 Actuator with 1400‑60cm² actuator area
Note

20 EB 8059 EN
Measures for preparation
4 Measures for preparation
After receiving the shipment, proceed as fol-
lows:
1. Check the scope of delivery. Compare
the shipment received with the delivery
note.
2. Check the shipment for transportation
damage. Report any damage to
SAMSON and the forwarding agent
(refer to delivery note).
4.1 Unpacking
Do not remove the packaging until immedi-
ately before installing the valve into the pipe-
line.
Proceed as follows to lift and install the
valve:
1. Remove the packaging from the valve.
2. Dispose of the packaging in accordance
with the valid regulations.
Risk of valve damage due to foreign parti-
cles entering the valve.
The protective caps tted on the valve's inlet
and outlet prevent foreign particles from en-
tering the valve and damaging it.
Do not remove the protective caps until im-
mediately before installing the valve into the
pipeline.
4.2 Transporting and lifting
Hazard due to suspended loads falling.
Stay clear of suspended or moving loads.
Risk of lifting equipment tipping and risk of
damage to lifting accessories due to exceed-
ing the rated lifting capacity.
−Only use approved lifting equipment and
accessories whose minimum lifting capaci-
ty is higher than the weight of the valve
(including actuator, if applicable).
−Refer to the Data Sheet uT8059 for
weights.
Risk of personal injury due to the control
valve tipping.
−Observe the valve's center of gravity.
−Secure the valve against tipping over or
turning.
Note
NOTICE
!
DANGER
!
WARNING
!
WARNING
!