Samson 3522 Service manual

Translation of original instructions
EB 8822 EN
Type3522 Globe Valve·ANSI version
In combination with an actuator,
e.g. a Type3271 or Type3277 Pneumatic Actuator
Edition September 2021

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 8822 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. 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
https://usa.samsongroup.com > Service & Support > Downloads >
Documentation.

Contents
EB 8822 EN
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..............................................................10
2 Markings on the control valve......................................................................12
2.1 Valve nameplate ..........................................................................................12
2.2 Actuator nameplate......................................................................................13
2.3 Material identication number ......................................................................13
3 Design and principle of operation ................................................................14
3.1 Fail-safe positions ........................................................................................16
3.2 Additional ttings.........................................................................................16
3.3 Accessories .................................................................................................16
3.4 Technical data .............................................................................................17
4 Shipment and on-site transport ....................................................................21
4.1 Accepting the delivered goods ......................................................................21
4.2 Removing the packaging from the valve.........................................................21
4.3 Transporting and lifting the valve...................................................................21
4.3.1 Transporting the valve ..................................................................................22
4.3.2 Lifting the valve............................................................................................24
4.4 Storing the valve..........................................................................................25
5 Installation..................................................................................................25
5.1 Installation conditions...................................................................................25
5.2 Preparation for installation............................................................................27
5.3 Mounting the device.....................................................................................28
5.3.1 Mounting the actuator onto the valve.............................................................28
5.3.2 Installing the valve into the pipeline ...............................................................29
5.4 Testing the installed valve..............................................................................30
5.4.1 Leak test......................................................................................................31
5.4.2 Travel motion...............................................................................................31
5.4.3 Fail-safe position..........................................................................................31
5.4.4 Pressure test.................................................................................................31
6 Start-up ......................................................................................................32
6.1 Start-up/putting the device back into operation..............................................33
6.2 Reversing the ow direction ..........................................................................33
7 Operation...................................................................................................33
7.1 Normal operation ........................................................................................34

Contents
EB 8822 EN
7.2 Manual operation ........................................................................................34
8 Malfunctions ...............................................................................................35
8.1 Troubleshooting ...........................................................................................35
8.2 Emergency action ........................................................................................36
9 Servicing.....................................................................................................37
9.1 Periodic testing ............................................................................................39
9.2 Preparing the valve for service work..............................................................40
9.3 Installing the valve after service work.............................................................40
9.4 Service work................................................................................................42
9.4.1 Replacing the body gasket............................................................................42
9.4.2 Replacing the packing..................................................................................42
9.4.3 Replacing the seat and plug..........................................................................44
9.5 Ordering spare parts and operating supplies .................................................45
10 Decommissioning ........................................................................................45
11 Removal .....................................................................................................46
11.1 Removing the valve from the pipeline.............................................................47
11.2 Removing the actuator from the valve ............................................................47
12 Repairs .......................................................................................................48
12.1 Returning devices to SAMSON .....................................................................48
13 Disposal......................................................................................................48
14 Certicates..................................................................................................49
15 Annex.........................................................................................................50
15.1 Tools, tightening torques and lubricants..........................................................50
15.2 Spare parts .................................................................................................52
15.3 After-sales service........................................................................................54

EB 8822 EN 5
Safety instructions and measures
1 Safety instructions and measures
Intended use
The SAMSON Type3522 Globe Valve in combination with an actuator (e.g. Type3271 or
Type3277 Pneumatic Actuator) is designed to regulate the ow rate, pressure or temperature
of liquids, gases or vapors. The valve is designed for use in light industrial applications.
The valve with its actuator is designed to operate under exactly dened conditions (e.g. oper-
ating pressure, process medium, temperature). Therefore, operators must ensure that the con-
trol 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 applica-
tions or conditions than specied, contact SAMSON.
SAMSON does not assume any liability for damage resulting from the failure to use the de-
vice for its intended purpose or for damage caused by external forces or any other external
factors.
ÎRefer to the technical data and nameplate for limits and elds of application as well as
possible uses.
Reasonably foreseeable misuse
The control valve is not suitable for the following applications:
− Use outside the limits dened during sizing and by the technical data
− Use outside the limits dened by the valve accessories connected to the valve
Furthermore, the following activities do not comply with the intended use:
− Use of non-original spare parts
− Performing service and repair work not described
− Qualications of operating personnel
The control valve must be mounted, started up, serviced and repaired by fully trained and
qualied personnel only; the accepted industry codes and practices must be observed. Ac-
cording to these mounting and operating instructions, trained personnel refers to individuals
who are able to judge the work they are assigned to and recognize possible hazards due to
their specialized training, their knowledge and experience as well as their knowledge of the
applicable standards.

6 EB 8822 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 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. 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.
Responsibilities of the operator
Operators are responsible for proper use and compliance with the safety regulations. Opera-
tors are obliged to provide these mounting and operating instructions to the operating per-
sonnel and to instruct them in proper operation. Furthermore, operators must ensure that op-
erating personnel or third parties are not exposed to any danger.

EB 8822 EN 7
Safety instructions and measures
Operators are additionally responsible for ensuring that the limits for the product dened in
the technical data are observed. This also applies to the start-up and shutdown procedures.
Start-up and shutdown procedures fall within the scope of the operator's duties and, as such,
are not part of these mounting and operating instructions. SAMSON is unable to make any
statements about these procedures since the operative details (e.g. differential pressures and
temperatures) vary in each individual case and are only known to the operator.
Responsibilities of operating personnel
Operating personnel must read and understand these mounting and operating instructions as
well as the referenced documents and observe the specied hazard statements, warnings
and caution notes. Furthermore, operating personnel must be familiar with the applicable
health, safety and accident prevention regulations and comply with them.
Referenced standards, directives and regulations
The SAMSON Type3522 Globe Valve complies with the requirements of ASMEB16.34,
ASMEB16.5 and ANSI/ISA75.08.01-2002 (R2007).
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 or uEB8313-X for SAMSON
Type3372 Actuator
− Mounting and operating instructions for mounted valve accessories (positioner, solenoid
valve etc.)
− When a substance is used in the device, which is listed as being a substance of very high
concern on the candidate list of the REACH regulation:
Information on safe use of the part affected
uwww.samsongroup.com > About SAMSON > Material Compliance > REACH
If a device contains a substance which is listed as being a substance of very high concern
on the candidate list of the REACH regulation, this circumstance is indicated on the
SAMSON delivery note.

8 EB 8822 EN
Safety instructions and measures
1.1 Notes on possible severe personal injury
DANGER
!
Risk of bursting in pressure equipment.
Valves and pipelines are pressure equipment. Impermissible pressure or improper open-
ing 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.
1.2 Notes on possible personal injury
WARNING
!
Risk of burn injuries due to hot or cold components and pipelines.
Depending on the process medium, valve components and pipelines may get very hot
or cold and cause burn injuries.
ÎAllow components and pipelines to cool down or warm up to the ambient tempera-
ture.
ÎWear protective clothing and safety gloves.
Risk of hearing loss or deafness due to loud noise.
The noise emissions depend on the valve version, plant facilities and process medium.
ÎWear hearing protection when working near the valve.
Risk of personal injury due to exhaust air being vented.
While the valve is operating, air is vented from the actuator, for example, during
closed-loop operation or when the valve opens or closes.
ÎInstall the control valve in such a way that vent openings 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.

EB 8822 EN 9
Safety instructions and measures
WARNING
!
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).
Risk of personal injury due to residual process medium in the valve.
While working on the valve, residual medium can ow out of the valve and, depending
on its properties, cause personal injury, e.g. (chemical) burns.
ÎIf possible, drain the process medium from all the plant sections affected and the
valve.
ÎWear protective clothing, safety gloves, respiratory protection and eye protection.

10 EB 8822 EN
Safety instructions and measures
WARNING
!
Exposure to hazardous substances poses a serious risk to health.
Certain lubricants and cleaning agents are classied as hazardous substances. These
substances have a special label and a material safety data sheet (MSDS) issued by the
manufacturer.
ÎMake sure that an MSDS is available for any hazardous substance used. If neces-
sary, contact the manufacturer to obtain an MSDS.
ÎInform yourself about the hazardous substances and their correct handling.
Risk of personal injury through incorrect operation, use or installation as a result of
information on the valve being illegible.
Over time, markings, labels and nameplates on the valve may become covered with dirt
or become illegible in some other way. As a result, hazards may go unnoticed and the
necessary instructions not followed. There is a risk of personal injury.
ÎKeep all relevant markings and inscriptions on the device in a constantly legible
state.
ÎImmediately renew damaged, missing or incorrect nameplates or labels.
1.3 Notes on possible property damage
NOTICE
!
Risk of valve damage due to contamination (e.g. solid particles) in the pipeline.
The plant operator is responsible for cleaning the pipelines in the plant.
ÎFlush the pipelines before start-up.
Risk of valve damage due to unsuitable medium properties.
The valve is designed for a process medium with dened properties.
ÎOnly use the process medium specied for sizing the valve.

EB 8822 EN 11
Safety instructions and measures
NOTICE
!
Risk of leakage and valve damage due to excessively high or low tightening torques.
Observe the specied torques when tightening control valve components. Excessive
tightening torques lead to parts wearing out more quickly. Parts that are too loose may
cause leakage.
ÎObserve the specied tightening torques (see section15.1).
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 (see section15.1).
Risk of valve damage due to the use of unsuitable lubricants.
The lubricants to be used depend on the valve material. Unsuitable lubricants may cor-
rode and damage surfaces.
ÎOnly use lubricants approved by SAMSON (see bill of materials and section15.1).

12 EB 8822 EN
Markings on the control valve
2 Markings on the control valve
2.1 Valve nameplate
Made in
USA
SAMSON 245
7818 9
10 11
15 16
14
13
6
2Type designation
4–
5 Material
6Year of manufacture
7 Order no. with modication index
8Order pos.
9 Conformity
10 Valve size NPS
11 Pressure rating (Cl.)
13 Flow coefcient
14 Characteristic:
%: equal percentage · Lin: linear
15 Seat-plug seal:
ME: metal
ST: base material with Stellite®facing or solid Stellite®
PT: soft seal with PTFE
16 Option code for trim identication (stem, plug, seat)
18 –
Fig.1: Type3522 nameplate
The nameplate is afxed to the back of the valve body.

EB 8822 EN 13
Markings on the control valve
2.2 Actuator nameplate
See associated actuator documentation.
2.3 Material identication
number
The seat and plug of the valves have an item
number written on them. You can contact us
stating this item number to nd out which
material is used. Additionally, a seat code is
used to identify the trim material (see Ta-
ble1). This seat code is specied on the
nameplate (seat/plug seal, 15). For more
details on the nameplate, see section2.1.
Table1: Seat codes
Valve Type3522
Plug stem material A479316/A479316L
Plug material A479316/A479316L A182F316/
A182F316L R30006 (Stellite® 6)
Seat material Seat code
A479316, A479316L 04 05 06
A182F316,
A182F316L 07 08 09

14 EB 8822 EN
Design and principle of operation
3 Design and principle of oper-
ation
The Type3522 Valve is a single-seated
globe valve. This valve is preferably com-
bined with a SAMSON Type3271 or
Type3277 Pneumatic Actuator (see Fig.2).
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 V-ring packing
(15). The springs in the pneumatic actuator
are located either above or below the dia-
phragm depending on the selected fail-safe
action (see section3.1). A change in the sig-
nal pressure acting on the diaphragm causes
the plug to move. The actuator size is deter-
mined by the diaphragm area.
The medium ows through the valve in the
direction indicated by the arrow. The valve
normally operates in the ow-to-open direc-
tion (FTO). The standard version normally
operates in the ow-to-open direction (FTO).
The medium ows across the plug from bot-
tom to top.
A rise in signal pressure causes the force act-
ing on the diaphragm in the actuator to in-
crease. The springs are compressed. De-
pending 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.
Actuators
In these instructions, the combination with a
Type3271 or Type3277 Pneumatic Actuator
is described. The pneumatic actuator 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.
As an alternative, the control valve can be
combined with a Type3372 Electropneumat-
ic Actuator (see uT8313).
Note

EB 8822 EN 15
Design and principle of operation
A7
84
A26/27
60
10
8
92
15
5
17
1
4
2
9
Fig.2: Type3522 Globe Valve with
threaded ends and Type3271
Pneumatic Actuator
Fig.3: Type3522 Globe
Valve with anges
1 Body
2 Bonnet
4Seat
5 Plug
8 Threaded bushing (packing
nut)
9Stem connector nut
10 Lock nut
15 Packing
17 Body gasket
60 Yoke assembly
84 Travel indicator scale
92 Nut
A7 Actuator stem
A26/27 Stem connector clamp

16 EB 8822 EN
Design and principle of operation
3.1 Fail-safe positions
The fail-safe position of the control valve up-
on air supply or control signal failure de-
pends on the actuator used (see associated
actuator documentation).
Depending on how the compression springs
are arranged in the SAMSON Type3271
and Type3277 Pneumatic Actuator, the
valve has one of two different fail-safe posi-
tions:
− Actuator stem extends (FA)
When the signal pressure is reduced or
the air supply fails, the springs move the
actuator stem downward and close the
valve. The valve opens when the signal
pressure is increased enough to over-
come the force exerted by the springs.
− Actuator stem retracts (FE)
When the signal pressure is reduced or
the air supply fails, the springs move the
actuator stem upwards and open the
valve. The valve closes when the signal
pressure is increased enough to over-
come the force exerted 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 Additional ttings
Strainers
We recommend installing a SAMSON
strainer upstream of the valve. It prevents sol-
id particles in the process medium from
damaging the valve.
Bypass and shut-off valves
We recommend installing a shut-off valve
both upstream of the strainer and down-
stream of the valve and installing a bypass
line. The bypass ensures that the plant does
not need to be shut down for service and re-
pair work on the valve.
Insulation
Do not insulate valves mounted to comply
with NACE MR0175 requirements.
Contact SAMSON’s After-sales Service in
case that insulation is required.
Safety guard
For operating conditions that require in-
creased safety (e.g. in cases where the valve
is freely accessible to untrained staff), a safe-
ty guard must be installed to rule out a crush
hazard arising from moving parts (actuator
and plug stem). Plant operators are responsi-
ble for deciding whether a guard is to be
used. The decision is based on the risk posed
by the plant and its operating conditions.
3.3 Accessories
Information Sheet uT8350
Tip
Note

EB 8822 EN 17
Design and principle of operation
3.4 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8822.
Temperature range
The valve is designed for a temperature
range from 14 to +430°F (–10 to +220°C).
Leakage class
Seal (15 on nameplate) ME, ST PT
Leakage class according
to ANSI/FCI70-2 IV or V VI
Noise emissions
SAMSON is unable to make general state-
ments about noise emissions. The noise emis-
sions depend on the valve version, plant fa-
cilities and process medium.
Dimensions and weights
Table2 to Table4 provide an overview of
the dimensions and weights of the threaded
and anged version of Type3522 Valve. The
lengths and heights are shown in the dimen-
sional drawings on pagep.18 and
p.19.
Note

18 EB 8822 EN
Design and principle of operation
Table2: Dimensions of Type3522 Valve · Version with threaded ends
Valve NPS ½ ¾ 1 1¼ 1½ 2
Length L Class300 in 3.5 3.5 4.31 4.63 5.31 6.66
mm 89 89 109 118 135 169
H1 for actuator
Type3271,
Type3277
≤350cm²
in 8.66 8.75 8.98
mm 220 222 228
Type3372 in 10.6 –
mm 269
H2 in 1.13 1.13 1.38 1.50 1.68 1.75
mm 28.5 28.5 35 38 43 44.5
Dimensional drawings
H2
L
H1
H2 H1
L
NPS½ to 1, threaded ends NPS1¼ to 2, threaded ends

EB 8822 EN 19
Design and principle of operation
Table3: Dimensions of Type3522 Valve · Version with anges
Valve Pressure
rating NPS ½ ¾ 1 1¼ 1½ 2
Length L
Class150 in 7.3 7.3 7.3 –8.7 10
mm 184 184 184 222 254
Class300 in 7.5 7.6 7.8 –9.3 10.5
mm 190 194 197 235 267
H1 for
actuator
Type3271,
Type3277
≤350cm²
in 8.66 –8.98
mm 220 –228
Type3372 in 10.6 –
mm 269
H2 in 1.3 1.2 1.4 –2.1 2.1
mm 33 31 36 –54.5 54.5
Dimensional drawings
L
H1
H2
L
H1H2
NPS½ to 1, anges NPS1½ to 2, anges

20 EB 8822 EN
Design and principle of operation
Table4: Weights of Type3522 Valve without actuator
Valve NPS ½ ¾ 1 1¼ 1½ 2
Version with threaded
ends
lbs 7 7.5 9 11 12 17
kg 3 3.4 4 5 5.4 7.7
Version with anges lbs 11.5 14.8 16.8 –31.1 34.6
kg 5.2 6.7 7.6 –14.1 15.7
Refer to the following data sheets for more dimensions and weights:
uT8310-1 for Type3271 or Type3277 Pneumatic Actuators up to 750cm² actuator area
uT8313 for Type3372 Electropneumatic Actuator
Note