Samson 3595 Service manual

Translation of original instructions
EB 8079 EN
Edition November 2019
Type3595 Valve · ANSI version
For combination with actuators,
such as Type3276 or Type3271 Pneumatic Actuators
Type3595 Valve with Type 3271 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. 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
Department ([e-mail]).
The mounting and operating instructions for the devices are included in
the scope of delivery. The latest documentation is available on our web-
site at www.samsongroup.com > Service & Support > Downloads > Doc-
umentation.
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 8079 EN

Contents
EB 8079 EN
1 Safety instructions and measures ................................................................1-1
1.1 Notes on possible severe personal injury ......................................................1-4
1.2 Notes on possible personal injury ................................................................1-4
1.3 Notes on possible property damage .............................................................1-6
2 Markings on the device ..............................................................................2-1
2.1 Valve nameplate .........................................................................................2-1
2.2 Actuator nameplate .....................................................................................2-1
3 Design and principle of operation ...............................................................3-1
3.1 Fail-safe positions .......................................................................................3-1
3.2 Versions .....................................................................................................3-3
3.3 Additional ttings ........................................................................................3-4
3.4 Technical data ............................................................................................3-4
4 Shipment and on-site transport ...................................................................4-1
4.1 Accepting the delivered goods .....................................................................4-1
4.2 Removing the packaging from the valve ........................................................4-1
4.3 Transporting and lifting the valve ..................................................................4-1
4.3.1 Transporting the valve .................................................................................4-2
4.3.2 Lifting the valve ...........................................................................................4-4
4.4 Storage ......................................................................................................4-5
5 Installation.................................................................................................5-1
5.1 Installation conditions ..................................................................................5-1
5.2 Preparation for installation ...........................................................................5-4
5.3 Mounting the device ....................................................................................5-4
5.3.1 Mounting the actuator onto the valve ............................................................5-5
5.3.2 Installing the valve into the pipeline ..............................................................5-5
5.4 Testing the installed valve .............................................................................5-6
5.4.1 Leak test .....................................................................................................5-7
5.4.2 Travel motion ..............................................................................................5-7
5.4.3 Fail-safe position .........................................................................................5-8
5.4.4 Pressure test ................................................................................................5-8
6 Start-up .....................................................................................................6-1
7 Operation..................................................................................................7-1
7.1 Working in closed-loop operation ................................................................7-1
7.2 Working in manual mode ............................................................................7-2
7.3 Lubricator for the packing chamber ..............................................................7-2

Contents
EB 8079 EN
8 Malfunctions ..............................................................................................8-1
8.1 Troubleshooting ..........................................................................................8-1
8.2 Emergency action .......................................................................................8-3
9 Servicing....................................................................................................9-1
9.1 Periodic testing ...........................................................................................9-3
9.2 Preparing the valve for service work .............................................................9-3
9.3 Mounting the valve after service work ...........................................................9-4
9.4 Service work...............................................................................................9-4
9.4.1 Replacing the gaskets ..................................................................................9-4
9.4.2 Replacing the packing .................................................................................9-5
9.4.3 Replacing the bellows seal ...........................................................................9-6
9.4.4 Lapping the seat and plug ...........................................................................9-7
9.5 Ordering spare parts and operating supplies ................................................9-9
10 Decommissioning .....................................................................................10-1
11 Removal ..................................................................................................11-1
11.1 Removing the valve from the pipeline ..........................................................11-1
11.2 Removing the actuator from the valve .........................................................11-2
12 Repairs ....................................................................................................12-1
12.1 Returning devices to SAMSON ..................................................................12-1
13 Disposal...................................................................................................13-1
14 Certicates...............................................................................................14-1
15 Annex......................................................................................................15-1
15.1 Tightening torques, lubricants and tools ......................................................15-1
15.2 Spare parts ..............................................................................................15-3
15.3 After-sales service .....................................................................................15-3

EB 8079 EN 1-1
Safety instructions and measures
1 Safety instructions and measures
Intended use
The SAMSON Type3595 Globe or Angle Valve in combination with an actuator (e.g.
Type3276 or Type3271 Pneumatic Actuator) is designed to regulate the ow rate, pressure
or temperature of liquids, gases or vapors. The valve is suitable for throttling and on/off ser-
vice in the oil and gas industry as well as for high-temperature applications in power plants.
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 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.
Explosion-protected versions of this device must be operated only by personnel who has un-
dergone special training or instructions or who is authorized to work on explosion-protected
devices in hazardous areas.

1-2 EB 8079 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, safety gloves and eye 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 features
The fail-safe position of the control valve upon air supply or control signal failure depends on
the actuator used (see associated actuator documentation). For example, when the valve is
combined with a SAMSON Type3271 Pneumatic Actuator, the valve moves to a certain fail-
safe position (see the 'Design and principle of operation' section) upon supply air or control
signal failure. The fail-safe action of the actuator is the same as its direction of action and is
specied on the nameplate of SAMSON actuators.
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.
Furthermore, the intended purpose may involve the use of the device in hazardous areas. In
this case, all work on the control valve must only be performed when no potentially explosive
atmosphere is present.

EB 8079 EN 1-3
Safety instructions and measures
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
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 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 a declaration of conformity, which in-
cludes information about the applied conformity assessment procedure. The 'Certicates' sec-
tion contains this declaration of conformity.
Non-electric valve versions whose bodies are not lined with an insulating material coating do
not have their own potential ignition source according to the risk assessment stipulated in
EN13463-1:2009, section5.2, even in the rare incident of an operating fault. Therefore,
such valve versions 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0165-1).
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8318 for
Type3276 Actuator or uEB8310-X for Type3271 Actuator
−Mounting and operating instructions for mounted valve accessories (positioner, solenoid
valve etc.)
−For oxygen service 1): Manual uH01
1) See information on order-specic installation drawing

1-4 EB 8079 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
opening 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 af-
fected 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 heat up.
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, the actuator or valve accessories may vent during closed-
loop control or when the valve opens or closes.
ÎInstall the control valve in such a way that vent holes 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 8079 EN 1-5
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.
SAMSON piston actuators do not carry any label concerning preloading of the actua-
tor springs.
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 affected and the
valve.
ÎWear protective clothing, safety gloves and eye protection.

1-6 EB 8079 EN
Safety instructions and measures
WARNING
!
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.
Risk of leakage and valve damage due to excessively high or low tightening torques.
Observe the specied torques on tightening control valve components. Excessively tight-
ened torques lead to parts wearing out quicker. Parts that are too loose may cause leak-
age.
ÎObserve the specied tightening torques (see the 'Tightening torques, lubricants and
tools' section in the annex of these instructions).
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 the 'Tightening torques, lubricants and
tools' section in the annex of these instructions).

EB 8079 EN 1-7
Safety instructions and measures
NOTICE
!
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 surface.
ÎOnly use lubricants approved by SAMSON (see the 'Tightening torques, lubricants
and tools' section in the annex of these instructions).
Risk of contamination of the process medium through the use of unsuitable lubricants
and/or contaminated tools and components.
ÎIf necessary, keep the valve and the tools used free from solvents and grease.
ÎMake sure that only suitable lubricants are used.

1-8 EB 8079 EN

EB 8079 EN 2-1
Markings on the device
2 Markings on the device
2.1 Valve nameplate
The valve nameplate describes the key char-
acteristics of the valve, such as:
−Type designation
−Valve size
−Pressure rating
−Date of manufacture
−Serial number
It is located on the valve body.
2.2 Actuator nameplate
See associated actuator documentation.

2-2 EB 8079 EN
Markings on the device
The location of the valve nameplate varies
depending on the valve size:
−Valve body
−Yoke

EB 8079 EN 3-1
Design and principle of operation
3 Design and principle of oper-
ation
See Fig.3-1
Valve style and actuator
The Type3595 Valve is a cage valve de-
signed as globe or angle valve. The valve
can be combined with various electric, elec-
trohydraulic and pneumatic actuators. This
documentation includes examples of the
combination with the Type3276 or
Type3271 Pneumatic Actuator.
Cage valve
Different valve trims are used in the
Type3595 Valve to meet application re-
quirements. All valve trims have a plug
which is guided through a cage with very lit-
tle clearance over the entire stroke. This cage
guide suppresses vibration of the closure
member, resulting in a better control perfor-
mance at high energy forces created by
changes in pressure and ow rate. The plug
is available with or without pressure balanc-
ing.
Design
The plug is connected to the plug stem using
a form-t connection. The plug stem is con-
nected to the actuator stem by a stem con-
nector which transfers the linear motion of
the actuator to the valve plug. The actuator is
connected using a special assembly, which
varies depending on the mounted actuator.
These assemblies are tted with an external
anti-rotation xture for the plug stem.
The plug stem in the valve bonnet is sealed
by either a PTFE or graphite packing, which
is either self adjusting or can be adjusted
manually.
The valve has a clamped-in seat. The seat is
inserted into the seat bridge. The seat and
cage are clamped into place by tightening
the body nuts.
Function
The medium ows through the valve as indi-
cated by the arrow on the valve body. A
change in the pneumatic signal acting on the
actuator changes the plug travel and how
far the valve is opened as a result. The plug
position and cage design determine the re-
leased cross-section and the resulting ow
rate.
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
Pneumatic Actuator, the valve has two differ-
ent fail-safe positions:
−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.

3-2 EB 8079 EN
Design and principle of operation
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
Fig.3-1: Type3595 Valve with Type3271 Actuator

EB 8079 EN 3-3
Design and principle of operation
−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
3.2 Versions
Actuators
In these instructions, the preferable combina-
tion with a SAMSON Type3276 or
Type3271 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.
Tip
Note
Legend for Fig.3-1
1Valve body
2Plug stem
3 Valve bonnet
4 Body nut
5 Stud bolt (valve body)
6 Screw (yoke)
7 Packing gland
8Yoke
9Actuator connection assembly
10 Actuator
11 Actuator stem
12 Travel indicator scale
13 Nut (packing gland)
14 Stud bolt (packing gland)
15 Packing follower
16 Packing rings
17 Guide bushing
18 Gasket (valve body)
19 Gasket (valve bonnet)
20 Cage
21 Gasket (cage)
22 Plug
23 Cage
24 Seat ring
25 Gasket (seat ring)

3-4 EB 8079 EN
Design and principle of operation
The basic pneumatic actuator can be re-
placed by an actuator with additional
handwheel, an electric actuator or an hy-
draulic piston actuator.
Bellows seal
The valve can be tted with a bellows seal to
meet special requirements resulting from the
process medium used.
3.3 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 line ensures that the plant
does not need to be shut down for service
and repair work on the valve.
Insulation
Control valves can be insulated to reduce
heat energy transfer.
Refer to the instructions in the 'Installation'
section.
Safety guard
For operating conditions, which 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.
3.4 Technical data
The nameplates on the valve and actuator
provide information on the control valve ver-
sion. See the 'Markings on the device' sec-
tion.
Further technical data for the valve are
available in the Data Sheet uT8079, for
actuators in the associated data sheets, for
example uT8318 for Type3276 Actuator
or uT8310-X for Type3271 Actuator.
Noise emissions
SAMSON is unable to make general state-
ments about noise emissions. The noise emis-
sions depend on the valve version (e.g. with
cage), plant facilities and process medium.
Note

EB 8079 EN 3-5
Design and principle of operation
Table 3-1: Technical data
Type 3595 Globe Valve Cast body Forged body
Valve size NPS¾ to 2 NPS3 to 32 NPS¾ to 2 NPS3 to 12
Pressure rating Class150 to 2500
Type of con-
nection
Flanges ••••
Welding ends ••••
Welding-neck
ends ••••
Characteristic Equal percentage · Linear · Others on request
Compliance
Maximum permissible temperature range and leakage class according to IEC60534-4
Valve trim
USS/STD™
USS/LDB™ –325 to +1292°F/–196 to +700°C
BSS/STD™
BSS/LDB™
Leakage class IV, V and VI: –325 to +482°F/
–196 to +250°C
CAVLESS™ Leakage class IV, V and VI: –325 to +482°F/
–196 to +250°C
PILOT/STD™
PILOT/LDB™
Leakage class V: –4 to +1292°F/
–20 to +700°C
MULTICYL™ Leakage class IV, V and VI: –325 to +482°F/
–196 to +250°C
Table 3-2: Materials
Type 3595 Globe Valve Cast body Forged body
Valve
body and
valve bon-
net
Standard
materials
Cast steel or
forged steel A216WCB A105
High-tempera-
ture cast steel
or forged steel
A217WC6
A217WC9
A182F11
A182F22
Stainless steel A351CF8M A182F316
Special
materials
Duplex steel A351-CK3MCuN
A890Gr.4ACD3MN
A182F44
A182F51
Super duplex
steel
A890Gr.5ACE3MN
A890Gr.6ACD3MWCuN
A182F53
A182F55
Inconel®A494CW6MC B564N06625
Valve trim (seat, plug, cage etc.)
AISI410, AISI420, AISI316 and Stellite®or other
hard-facing alloy A182F44, A182F53, A182F55,
B564N06625

3-6 EB 8079 EN
Design and principle of operation
Table 3-3: Dimensions of Type3595 Valve · Valve body with welding ends or welding-neck
ends
Table3-3.1: NPS¾ to 4 · Dimensions in inches and mm
Valve size NPS
Dimension Pressure rating ¾ 1 1½ 2 34
Length L
Class150
to 600
in 7.36 7.36 8.74 10.00 12.52 14.49
mm 187 187 222 254 318 368
Class900
and 1500
in 7.64 7.76 9.25 11.50 12.52 14.49
mm 194 197 235 292 318 368
Class2500 in 8.50 8.50 10.24 12.52 15.00 15.98
mm 216 216 260 318 381 406
Height H2
Class150
to 600
in On request 1.69 3.15 2.52 3.15 5.71
mm On request 43 80 64 80 145
Class900
to 1500
in On request 2.68 3.35 3.58 4.84 5.94
mm On request 68 85 91 123 151
Class2500 in On request 2.8 On request 3.86 On request 6.26
mm On request 71 On request 98 On request 159
Height H4
Class150
to 600
in 7.6 7.6 7.76 8.54 10.91 12.76
mm 193 193 197 217 277 324
Class900
to 1500
in 8.66 8.66 9.49 9.96 12.13 12.32
mm 220 220 241 253 308 313
Class2500 in 10.04 10.04 10.83 11.54 12.87 14.53
mm 255 255 275 293 327 369
Height H3
with
Type3276
Actuator1)
Class150
to 2500
in 3.94 3.94 3.94 3.94 4.92 5.91
mm 100 100 100 100 125 150
Height H8
2)
Class150
to 2500
in On request On request On request On request On request On request
mm On request On request On request On request On request On request
1) H3 with Type3271 Actuator, seeTable 3-7
2) Only with Type3271 Actuator