Samson 3286 Service manual

Mounting and
Operating Instructions
EB 8257 EN
Translation of original instructions
Edition March 2017
Type3286 Steam Conditioning Valve
In combination with an actuator,
e.g. a SAMSON Type3271 or Type3277 Pneumatic Actuator
ANSI version

2 EB 8257 EN
Note on these mounting and operating instructions
These mounting and operating instructions assist you in mounting and operating the device
safely. The instructions are binding for handling SAMSON devices.
ÎFor the safe and proper use of these instructions, read them carefully and keep them for
later reference.
ÎIf you have any questions about these instructions, contact SAMSON‘s After-sales Service
Department (aftersalesser[email protected]).
The mounting and operating instructions for the devices are included in
the scope of delivery. The latest documentation is available on our website
(www.samson.de) > Product documentation. You can enter the document
number or type number in the [Find:] eld to look for a document.
Denition of signal words
Hazardous situations which, if not avoided,
will result in death or serious injury
Hazardous situations which, if not avoided,
could result in death or serious injury
Property damage message or malfunction
Additional information
Recommended action
DANGER
!
WARNING
!
NOTICE
!
Note
Tip

Contents
EB 8257 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 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 .............................................................................................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..........................................................................................................21
4.3 Storage.......................................................................................................24
4.4 Preparation for installation............................................................................25
5 Mounting and start-up.................................................................................26
5.1 Mounting the actuator onto the valve.............................................................26
5.2 Installing the valve into the pipeline ...............................................................27
5.2.1 Checking the installation conditions...............................................................27
5.2.2 Additional ttings.........................................................................................28
5.2.3 Installing the control valve.............................................................................29
5.3 Putting the control valve into operation...........................................................30
5.4 Quick check ................................................................................................30
6 Operation...................................................................................................32
6.1 Working in manual mode.............................................................................32
7 Servicing.....................................................................................................34
7.1 Preparing the valve for servicing ...................................................................35

4 EB 8257 EN
Contents
7.2 Replacing gaskets ........................................................................................35
7.3 Replacing the packing..................................................................................38
7.4 Replacing the seat and plug..........................................................................40
7.5 Determining the number of shims required.....................................................42
7.6 Completion of servicing activities...................................................................42
7.7 Preparation for return shipment.....................................................................44
7.8 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 ............................................................49
9.4 Disposal......................................................................................................49
10 Annex.........................................................................................................50
10.1 After-sales service........................................................................................50
10.2 Certicates ..................................................................................................50
10.3 Spare parts .................................................................................................53

EB 8257 EN 5
Safety instructions and measures
1 Safety instructions and measures
Intended use
The SAMSON Type3286 Steam Conditioning Valve in combination with an actuator (e.g.
Type3271 or Type3277 Pneumatic Actuator) is designed to regulate the pressure and
temperature of steam. The valve is intended for use in for process engineering applications
and thermal plants. 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 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, contact SAMSON.
SAMSON does not assume any liability for damage resulting from the failure to use the
valve for its intended purpose or for damage caused by external forces or any other external
factors.
ÎRefer to the technical data and nameplate for limits and elds of application as well as
possible uses.
Reasonably foreseeable misuse
The control valve is not suitable for the following applications:
−Use outside the limits dened during sizing and in the technical data
−Use outside the limits dened by the valve accessories mounted on the control valve
Furthermore, the following activities do not comply with the intended use:
−Use of non-original spare parts
−Performing service and repair work not described in these instructions
Qualications of operating personnel
The control valve must be mounted, started up, serviced, and repaired by fully trained and
qualied personnel only; the accepted industry codes and practices are to be observed.
According to these mounting and operating instructions, trained personnel refers to
individuals who are able to judge the work they are assigned to and recognize possible
hazards due to their specialized training, their knowledge and experience as well as their
knowledge of the applicable standards.

6 EB 8257 EN
Safety instructions and measures
Personal protective equipment
We recommend wearing the following protective equipment depending on the process
medium:
−Protective clothing, gloves, and eyewear in applications with hot, cold, and/or corrosive
media
−Wear hearing protection when working near the valve.
ÎCheck with the plant operator for details on further protective equipment.
Revisions and other modications
Revisions, conversions or other modications to the product are not authorized by SAMSON.
They are performed at the user's own risk and may lead to safety hazards, for example.
Furthermore, 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
operating 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 operating instructions, especially for installation, start-up, and service work.
Responsibilities of the operator
The operator is responsible for proper operation and compliance with the safety regulations.
Operators are obliged to provide these mounting and operating instructions as well as the
referenced documents to the operating personnel and to instruct them in proper operation.
Furthermore, the operator must ensure that operating personnel or third persons are not ex-
posed to any danger.
Responsibilities of operating personnel
Operating personnel must read and understand these mounting and operating instructions as
well as the referenced documents and observe the hazard statements, warning and caution
notes specied in them. Furthermore, the operating personnel must be familiar with the ap-
plicable health, safety and accident prevention regulations and comply with them.

EB 8257 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 (positioner, solenoid
valve etc.)
−uAB0100 for tools, tightening torques, and lubricant

8 EB 8257 EN
Safety instructions and measures
1.1 Notes on possible severe personal injury
DANGER
!
Risk of bursting in pressure equipment.
Control valves and pipelines are pressure equipment. Improper opening can lead to
valve components bursting.
ÎBefore starting any work on the control valve, depressurize all plant sections
concerned as well as the valve.
ÎDrain the process medium from all the plant sections concerned as well as the
valve.
ÎWear personal protective equipment.
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 8257 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
tension. 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.
ÎPickle and blow through the steam pipe.
ÎObserve the maximum permissible pressure for valve and plant.

10 EB 8257 EN
Safety instructions and measures
NOTICE
!
Risk of valve damage due to unsuitable medium properties.
The valve is designed for steam and cooling water.
ÎMake sure that the steam and cooling water are clean and free of mineral
components.
ÎInstall strainers.
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 cor-
rode and damage the valve surface.
ÎOnly use lubricants approved by SAMSON (uAB0100).

EB 8257 EN 11

12 EB 8257 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 18
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
9Year of manufacture
10 Valve size:
DIN: DN · ANSI: NPS
11 Pressure rating:
DIN: PN · ANSI: CL
12 Order no. with modication index
For after-sales service orders: AA prex
13 Position in order
For after-sales service orders: conguration ID
14 Flow coefcient:
DIN: KVS · ANSI: CV
15 Characteristic:
%: equal percentage · Lin: linear
16 Seat-plug seal:
ME: metal (see section3.3)
HA: carbide metal
ST: Stellite®facing
17 Seat code (trim material) · On request
18 Pressure balancing:
DIN: D · ANSI: B
19 Flow divider:
3: ST3
20 Country of origin

EB 8257 EN 13
Markings on the control valve
The nameplate (80) is afxed to the yoke of
the valve (see Fig.2).
80
Fig.2: Location of the nameplate
2.2 Actuator nameplate
See associated actuator documentation.
2.3 Material number
The seat and plug of the valves have an
article 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 8257 EN
Design and principle of operation
3 Design and principle of oper-
ation
The single-seated Type3286 Angle Valve
acts as a steam conditioner and is tted with
a ow divider ST3. The Type3286 Steam
Conditioning Valve is preferably combined
with a SAMSON Type3271 or Type3277
Pneumatic Actuator (see Fig.3). It can also
combined with other actuators.
The seat (4), ow divider (62), 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
V-ring packing (15). Alternatively, an adjust-
able high-temperature packing can be used.
The springs in the pneumatic actuator are
located either above or below the
diaphragm (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 and the pres-
sure p2as well.
The cooling water is fed to the ow divider
(62) through the connecting pipe on the bon-
net (2) and holes in the clamping element
(63). After owing through the cross-section-
al area between seat and plug, the steam
ow reaches its maximum velocity and
comes into contact with the cooling water at
the inner wall of the ow divider. The steam
ow and the entrained water are mixed in
the narrow wire mesh of the ow divider. At
the same time, the steam velocity is reduced,
releasing some of its heat to the water across
the large surface of the wire mesh coil,
which causes it to evaporate quickly. The
steam/water mixture leaves the ow divider
as a ne mist with a high steam content.
Evaporation is completed a short distance
downstream of the steam conditioning valve.
The water atomization described is ensured
over the whole load range since the steam
velocity at the throttling point is independent
of the ow rate.
3.1 Fail-safe positions
The fail-safe position depends on the mount-
ed actuator.
Depending on how the compression springs
are arranged in the pneumatic actuator, the
valve has two different fail-safe positions:
Actuator stem extends (FA)
When the signal pressure is reduced or the
air supply fails, the springs move the actua-
tor stem downward and close the valve. The
valve opens when the signal pressure is in-
creased enough to overcome the force exert-
ed by the springs.

EB 8257 EN 15
Design and principle of operation
1 Body
2 Bonnet (with connecting pipe)
3Yoke
4Seat
5 Plug (with plug stem)
7Guide bushing
8 Threaded bushing (packing nut)
9 Stem connector nut
10 Lock nut
14 Body nut
15 Packing
17 Body gasket
62 Flow divider ST3
63 Clamping element
84 Travel indicator scale
92 Castellated nut
A4 Diaphragm
A7 Actuator stem
A8 Ring nut
A10 Spring
A26/27 Stem connector clamps
S Signal pressure connection
Superheated
steam
Water
Throttled and
cooled steam
p3
t3
p2
t2
p3t3
S
A8
A4
A10
A7
A26/27
63
62
4
5
17
14
15
92
8
10
9
84
3
2
7
1
Fig.3: Type3286 Valve with Type3271 Pneumatic Actuator

16 EB 8257 EN
Design and principle of operation
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
The modular design allows an insulating sec-
tion or metal bellows to be tted to the stan-
dard valve version.
Actuators
In these instructions, the preferable
combination with a Type3271 or Type3277
Pneumatic 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.
The basic pneumatic actuator can be re-
placed by a pneumatic actuator with addi-
tional handwheel or by an electric 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.
More information is available in Data Sheet
uT8257.
Noise emission
SAMSON is unable to make general
statements about noise emission as it
depends on the valve version, plant facilities,
and process medium. On request, SAMSON
can perform calculations according to
IEC60534, Part8-3 and Part8-4 or
VDMA24422 (edition 89).
Risk of hearing loss or deafness due to loud
noise.
Wear hearing protection when working near
the valve.
Tip
Note
Note
WARNING
!

EB 8257 EN 17
Design and principle of operation
Table1: Technical data for Type3286
Material Cast steel · A216 WCC Cast steel · A217 WC6
Valve size NPS 2 to 12
Pressure rating Class 150 to 900
Type of connection Flanges ASMEB16.5
Welding ends ASMEB16.25
Seat-plug seal Metal seal or high-performance metal seal
Characteristic Equal percentage or linear
Rangeability 50:1
Compliance ·
Temperature ranges · Permissible operating pressures acc. to pressure-temperature diagrams (see
Information Sheet uT8000-2)
Body without insulating section 14 to 428°F (–10 to +220°C) · Up to 660°F (up to
350°C) with high-temperature packing
Body with Insulating section –20 to +800°F (–29 to
+427°C)
–20 to +932°F (–29 to
+500°C)
Valve
plug
Standard Metal seal –20 to +932°F (–29 to 500°C)
Balanced with PTFE –20 to +428°F (–29 to +220°C)
Balanced with graphite ring –20 to +932°F (–29 to +500°C)
Leakage class according to ANSI/FCI70-2
Valve
plug
Standard
Metal seal IV
High-performance
metal seal V
Balanced with PTFE Standard: IV · High-performance metal seal: V
Balanced with graphite ring IV
Dimensions and weights
Table2 and Table3 provide a summary of the dimensions and weights of the standard ver-
sion of Type3286 Valve. The lengths and heights in the dimensional drawing are shown on
p.18.
Dimensions in mm · Weights in kg

18 EB 8257 EN
Design and principle of operation
Dimensional drawing
The dimensions H6 and L3 for the cooling
water connection are available on request.
Refer to the following data sheets for more
dimensions and weights:
uT8257 for valves with bellows seal or
insulating section
The associated actuator documentation ap-
plies to actuators, e.g. for SAMSON pneu-
matic actuators:
uT8310‑1 for Type3271 and Type3277
Actuators up to 750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
L2
L2
H6
L3
H8
H4
Type3286 Valve with anges
Table2: Dimensions for Type3286 Valve · Face‑to face dimensions according to ANSI/ISA‑
75.08.01 for Class600 and lower and according to ASME B16.10 for Class900 and
higher
Valve NPS 2 3 4 6 8 10 12
DN 50 80 100 150 200 250 300
Length L2
Class150 in 5.00 5.88 6.94 8.88 10.69
On request
mm 127 149 176 226 272
Class 300 in 5.25 6.25 7.25 9.31 11.19
mm 133 159 184 236 284
Class 600 in 5.62 6.62 7.75 10.00 12.00
mm 143 168 197 254 305
Class 900 in 7.25 7.50 9.00 12.00 14.50
mm 184 190 229 305 368
Height
H4
Class 150 to
600
in 6.89 6.30 6.69 9.13
On request
mm 175 160 170 210
Class 900 in 8.70 6.30 6.69 9.13
mm 221 160 170 210
Note

EB 8257 EN 19
Design and principle of operation
Valve NPS 2 3 4 6 8 10 12
DN 50 80 100 150 200 250 300
H8 for
actuator
350cm² in 9.45 9.45 9.45 –
mm 240 240 240
355cm²
in 9.45 9.45 9.45 16.46
–
mm 240 240 240 418
700cm²
in 9.45 9.45 9.45 16.46 16.46 –
mm 240 240 240 418 418
750cm² in 9.45 9.45 9.45 16.46 16.46 16.46 –
mm 240 240 240 418 418 418
1000cm² in 11.61 11.61 11.61 16.46 16.46 –
mm 295 295 295 418 418
1400-60cm² in 11.61 11.61 11.61 16.46 16.46 19.81 19.81
mm 295 295 295 418 418 503 503
1400-120cm² in 18.90 18.90 18.90 19.81 19.81 19.81 19.81
mm 480 480 480 503 503 503 503
2800cm² in 18.90 18.90 18.90 19.81 19.81 25.60 25.60
mm 480 480 480 503 503 650 650
2x2800cm² in 18.90 18.90 18.90 19.81 19.81 19.811) 25.60
mm 480 480 480 503 503 5031) 650
1) H8 = 25.60" (650 mm) with 9.84" (250 mm) seat bore
Table3: Weights for Type3286
Valve
NPS 2 3 4 6 8 10 12
DN 50 80 100 150 200 250 300
Valve
without
actuator
Class150 lbs 66 110 152 342 948 1892 2028
kg 30 50 69 155 460 858 920
Class 300 lbs 95 170 247 694 948 1892 2028
kg 43 77 112 315 430 858 920
Class 600 lbs 95 170 247 694 1096 2509 2535
kg 43 77 112 315 497 1138 1150
Class 900 lbs 95 170 247 694 1157 2844 3263
kg 43 77 112 315 525 1290 1480

20 EB 8257 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 against the deliv-
ery 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
capacity is higher than the weight of the
valve (including actuator, if applicable).
−Refer to section3.3 or Data Sheet
uT8257 for weights.
Risk of personal injury due to control valve
tipping.
−Observe the valve's center of gravity.
−Secure the valve against tipping over or
turning.
Note
NOTICE
!
DANGER
!
WARNING
!
WARNING
!