Samson 3525 Service manual

Mounting and
Operating Instructions
EB 8823 EN
Original instructions
Edition March 2017
Type3525 Globe Valve
In combination with an actuator
such as SAMSON Type3571 Pneumatic Actuator
ANSI version

2 EB 8823 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
future reference.
ÎIf you have any questions about these instructions, contact SAMSON‘s After-sales Service
Department ([email protected]).
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 or malfunction
Additional information
Recommended action
DANGER
!
WARNING
!
NOTICE
!
Note
Tip
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8820 for
Type3571 Pneumatic Actuator
−Mounting and operating instructions for mounted valve accessories (e.g. solenoid valve)
The mounting and operating instructions for all supplied devices are included in the delivery.
The latest versions of the documents are available on our website at
uwww.samsoncontrols.com.

Contents
EB 8823 EN 3
1 Safety instructions and safety measures .........................................................5
1.1 Notes on possible severe personal injury .........................................................7
1.2 Notes on possible personal injury ...................................................................7
1.3 Notes on possible property damage................................................................9
2 Markings on the control valve......................................................................10
2.1 Valve nameplate ..........................................................................................10
2.2 Actuator nameplate......................................................................................11
2.3 Material number..........................................................................................11
3 Design and principle of operation ................................................................12
3.1 Fail-safe positions ........................................................................................14
3.2 Technical data .............................................................................................15
4 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.......................................................................................................23
4.4 Preparation for installation............................................................................24
5 Mounting and start-up.................................................................................26
5.1 Mounting the actuator onto the valve.............................................................26
5.2 Installing the valve into the pipeline ...............................................................26
5.2.1 Checking the installation conditions...............................................................26
5.2.2 Additional ttings.........................................................................................28
5.2.3 Installing the control valve.............................................................................28
5.3 Quick check ................................................................................................29
6 Operation...................................................................................................30
6.1 Reversing the ow direction ..........................................................................30
7 Maintenance ...............................................................................................32
7.1 Standard version..........................................................................................33
7.1.1 Replacing the O-rings ..................................................................................33
7.1.2 Replacing the packing..................................................................................36
7.1.3 Replacing the seat and plug..........................................................................38
7.1.4 Tools and tightening torques..........................................................................39

4 EB 8823 EN
Contents
7.2 Compact version..........................................................................................40
7.2.1 Replacing the O-rings ..................................................................................40
7.2.2 Replacing the packing..................................................................................40
7.2.3 Replacing the seat and plug..........................................................................42
7.2.4 Tools and tightening torques..........................................................................44
7.3 Preparation for return shipment.....................................................................44
7.4 Ordering spare parts and operating supplies .................................................45
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 Appendix....................................................................................................50
10.1 Customer inquiries .......................................................................................50
10.2 Certicates ..................................................................................................50
10.3 Spare parts .................................................................................................52

EB 8823 EN 5
Safety instructions and safety measures
1 Safety instructions and safety measures
Intended use
The SAMSON Type3525 Globe Valve in combination with an actuator (e.g. Type3571
Pneumatic Actuator) is designed to regulate the ow rate, pressure or temperature of liquids,
gases or vapors. The valve is designed for use in high-pressure on/off applications in up-
stream and midstream oil and gas production.
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 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 8823 EN
Safety instructions and safety measures
Personal protective equipment
We recommend wearing the following protective equipment depending on the process medi-
um:
−Protective clothing, gloves and eyewear in applications with hot, cold and/or corrosive
media when working near or on the valve
−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. Furthermore, the
control valve 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 maintenance.
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 to the operating
personnel and to instruct them in proper operation. Furthermore, operators must ensure that
operating personnel or third persons are not exposed to any danger.
Responsibilities of operating personnel
Operating personnel must read and understand these mounting and operating instructions as
well as the specied hazard statements, warning and caution notes. Furthermore, the operat-
ing personnel must be familiar with the applicable health, safety and accident prevention
regulations and comply with them.

EB 8823 EN 7
Safety instructions and safety measures
Referenced standards and regulations
The SAMSON Type3525 Globe Valve complies with the requirements of ASMEB16.34.
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 con-
cerned and 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 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 vent plugs.
ÎWear eye protection when working in close proximity to the control valve.

8 EB 8823 EN
Safety instructions and safety measures
WARNING
!
Risk of personal injury due to sudden escape of process medium.
The valve has a safety bleed to detect damaged or worn O-rings. The process medium
may escape suddenly and at high pressure.
ÎWear protective clothing, gloves and eyewear when working near or on the valve.
ÎDo not stay in the range of the safety bleed longer than necessary.
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, 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 gloves.
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 preloaded
springs (see associated actuator documentation).

EB 8823 EN 9
Safety instructions and safety measures
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.
ÎFlush the pipelines before start-up.
ÎObserve the maximum permissible pressure for both the 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 the valve.
Risk of leakage and valve damage due to excessively high or low tightening torques.
Excessively tightened torques lead to parts wearing out quicker. Parts that are too loose
may cause leakage.
ÎObserve the specied tightening torques (see Table5 and Table6).
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).

10 EB 8823 EN
Markings on the control valve
2 Markings on the control valve
2.1 Valve nameplate
Made in
USA
SAMSON 24
35
7818 9
10 11 12
17
15 16
14
13
6
2Type designation
3Type version
C: compact · S: standard
4–
5Material
6Year of manufacture
7 Order number with modication index
8Item in order
9Conformity
10 Nominal size (NPS)
11 Pressure rating (Cl.)
12 For Intermediate Rating Standard Class: pressure and lower temperature limit
For other pressure ratings: lower temperature limit
13 Flow coefcient
14 Characteristic:
%: equal percentage · Lin: linear
15 Seat/plug sealing:
ME: metal
ST: metal base material stellited®or base material pure Stellite®
TC: tungsten carbide
16 Option code for trim identication (stem, plug, seat)
17 For Intermediate Rating Standard Class: pressure and upper temperature limit
For other pressure ratings: upper temperature limit
18 Not used
Fig.1: Type3525 nameplate

EB 8823 EN 11
Markings on the control valve
The valve nameplate is afxed to the rear of
the body.
80 80
Fig.2: Nameplate at the body
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
(seat/plug seal, 13). For more details on the
nameplate, see section2.1.
Standard version
Seat code Material
10 A351CF3M
11 Stellite®6
12 A747 CB7Cu1 H1150 DBL
14 WC/TC (HW-Co)/A747 CB7Cu1
H1150DBL
Compact version
Seat code Material
11 Stellite®6
13 WC/TC (HW-Co)/A479 XM-19-H

12 EB 8823 EN
Design and principle of operation
3 Design and principle of oper-
ation
The single-seated Type3525 Globe Valve is
combined with a SAMSON Type3571
Pneumatic Actuator (see Fig.4).
The seat (4) and plug with plug stem (5) are
assembled in the body (1). The plug stem is
connected to the actuator stem (A7) by the
stem connector clamps (A26) and is sealed
by a spring-loaded V-ring packing (16). The
springs in the pneumatic actuator (A) are lo-
cated either above or below the diaphragm
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 deter-
mined by the diaphragm area.
The medium ows through the valve in the
direction indicated by the arrow. The stan-
dard valve body version normally operates
in the ow-to-open direction (FTO). The me-
dium ows across the plug from bottom to
top. The compact valve body versions nor-
mally operate in the ow-to-close direction
(FTC). The medium ows across the plug
from top to bottom.
The valves have a safety bleed to detect
damaged or worn O-rings.
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.
There are three versions available:
−Standard globe valve with anges (see
Fig.3) or threaded ends
−Compact globe valve with threaded ends
−Compact T-pattern valve with threaded
ends (see Fig.5)
Standard globe valves >Class900 with FKM
O-ring are equipped with an additional sup-
port ring (244) which is inserted into the
groove of the bottom O-ring (17).
Compact T-pattern valves are equipped with
a screw plug (112). The screw plug can be
positioned either at the bottom outlet or –
depending on the ow direction – at the side
outlet. It must not be positioned at the inlet.
Actuators
In these instructions, the combination with a
Type3571 Pneumatic Actuator is described.
The pneumatic actuator for the standard ver-
sion can be replaced by another Type3571
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.
Note

EB 8823 EN 13
Design and principle of operation
17
17
244
Safety bleed
82
84
1
2
4
29
16
127
224
7
36
17
83
5
60
A28
12
11
15
1Body
2Bonnet
4Seat
5 Plug (29, 36)
7Guide bushing
11 Spring
12 Washer
15 Packing (11, 12, 16)
16 V-ring packing
17 O-ring
29 Plug head
36 Plug stem
60 Yoke assembly with
travel indicator
(82, 83, 84)
82 Screw
83 Hanger
84 Travel indicator scale
127 Seat ring gasket
224 Tab washer
244 Support ring
A7 Actuator stem
A28 Stem connector clamp
Fig.3: Standard version
Type3525 Globe
Valve with Type3571
Pneumatic Actuator
Fig.4: Bonnet for standard
version >Class900
with FKM O-ring

14 EB 8823 EN
Design and principle of operation
3.1 Fail-safe positions
The fail-safe position depends on the actua-
tor used.
Depending on how the compression springs
are arranged in the pneumatic actuator, the
valve has two different fail-safe positions:
Actuator stem extends
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
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
2Bonnet
3Yoke
4Seat
5 Plug (29, 36)
7Guide bushing
11 Spring
12 Washer
15 Packing (11, 12, 16)
16 V-ring packing
17 O-ring
29 Plug head
36 Plug stem
92 Lock nut
112 Screw plug
127 Seat ring gasket
A7 Actuator stem
A16 Vent plug
A28 Stem connector clamp
S Signal pressure connection
3
92
112
29
4
17
16
A7
A28
S
A16
1
2
36 5
7
12
11
15
127
Fig.5: Compact version Type3525
T-pattern Valve with Type3571
Pneumatic Actuator

EB 8823 EN 15
Design and principle of operation
3.2 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8823.
Temperature range
The valve version with an HNBR O-ring is
designed for a temperature range from –50
to +300°F (–46 to +149°C). By using an
FKM O-ring the temperature range can be
extended to –10 to +400°F (–23 to
+204°C). In case of oils that cause severe
swelling an FKM O-ring is to be used.
Leakage class
The leakage class according to ANSI/
FCI70-2 is IV for all sealing materials of the
seat/plug sealing (see pos. 12 on name-
plate: ME, ST, TC).
Noise emission
SAMSON is unable to make general state-
ments 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 (edi-
tion89).
Risk of hearing loss or deafness due to loud
noise.
Wear hearing protection when working near
the valve.
Dimensions and weights
Table1 and Table2 provide a summary of
the dimensions and weights of the standard
and compact version of Type3525 Valve.
The lengths and heights are shown in the di-
mensional drawings on p.16 (standard
version) and p.17 (compact version).
Note
WARNING
!

16 EB 8823 EN
Design and principle of operation
Table1: Dimensions of Type3525 Valve · standard version
Body
type
NPS 1 2 3
Version Standard globe valve
Connection RF RJF NPT RF RJF NPT RF RJF
L
Class600 in 8.27 8.27 –11.26 11.38 9.06 13.27 13.39
mm 210 210 –286 289 230 337 340
Class900 in 10.75 10.75 6.26 13.39 13.50 9.06 15.24 15.35
mm 273 273 159 340 343 230 387 390
Class1500 in 10.75 10.75 6.10 13.39 13.50 9.06 15.98 16.10
mm 273 273 155 340 343 230 406 409
Class1700 in – – 6.10 – – 9.06 – –
mm 155 230
H1 in 8.70 9.21 9.21
mm 221 234 234
H2 in 1.85 2.95 2.95
mm 47 75 75
Dimensional drawings
L
H2
H1
L
H2
H1
Standard globe valve, NPS1 to 3, anges Standard globe valve, NPS1 to 2,
threaded ends

EB 8823 EN 17
Design and principle of operation
Table2: Dimensions of Type3525 Valve · compact versions
Body
type
NPS 1
Version Compact
globe valve
Compact
T-pattern valve
Connection NPT NPT
L
Class600 in – –
mm
Class900 in 4.69 4.691)
mm 119 1191)
Class1500
Class1700
in – –
mm
H1 in 6.18 6.18
mm 157 157
H2 in 1.69 2.361)
mm 43 601)
1) Length without threaded stopper. This length can be extended by approx. 1.14 in/29mm depend-
ing on the position of the threaded stopper.
Dimensional drawings
L
H2
H1
L
H2
H1
Compact globe valve, NPS1 Compact T-pattern valve, NPS1

18 EB 8823 EN
Design and principle of operation
Table3: Weights for Type3525 Valve
Body type
NPS 1 2 3
Version Compact
globe valve
Compact
T-pattern
valve
Standard globe valve
Class600
RF/RTJ lbs – – 34.4 60.6 83.8
kg – – 15.6 27.5 38
NPT lbs – – – 44.1 –
kg –––20 –
Class900
RF/RTJ lbs – – 45.2 90.4/91.5 108.0
kg – – 20.5 41/41.5 49
NPT lbs 9.5 11.0 27.6 44.1 –
kg 4.3 5 12.5 20 –
Class1500
RF/RTJ lbs – – 45.2 90.4/91.5 135.6
kg – – 20.5 41/41.5 61.5
NPT lbs – – 27.6 44.1 –
kg – – 12.5 20 –
Class1700 NPT lbs – – 27.6 44.1 –
kg – – 12.5 20 –
Refer to the following data sheets for more dimensions and weights:
uT8820 for Type3571 Pneumatic Actuator
Note

EB 8823 EN 19

20 EB 8823 EN
Preparation
4 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 (re-
fer 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 section3.2 or Data Sheet
uT8823 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
!