Samson 36-3 Setup guide

Translation of original instructions
EB 2546-1 EN
Edition November 2018
Type36-3 Safety Shut-off Valve (SSV) with pressure reducing valve

Note on these mounting and operating instructions
These mounting and operating instructions assist you in mounting and operating the device
safely. The instructions are binding for handling SAMSON devices.
ÎFor the safe and proper use of these instructions, read them carefully and keep them for
later reference.
ÎIf you have any questions about these instructions, contact SAMSON‘s After-sales Service
Department (aftersalesser[email protected]).
The mounting and operating instructions for the devices are included in
the scope of delivery. The latest documentation is available on our website
at www.samson.de > Service & Support > Downloads > Documentation.
Denition of signal words
Hazardous situations which, if not avoided,
will result in death or serious injury
Hazardous situations which, if not avoided,
could result in death or serious injury
Property damage message or malfunction
Additional information
Recommended action
DANGER
!
WARNING
!
NOTICE
!
Note
Tip
2 EB 2546-1 EN

Contents
EB 2546-1 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..............................................................10
2 Markings on the device ...............................................................................11
2.1 Regulator nameplate ....................................................................................11
2.2 Material number..........................................................................................12
3 Design and principle of operation ................................................................12
3.1 Technical data .............................................................................................14
4 Measures for preparation before installation ................................................17
4.1 Unpacking ..................................................................................................17
4.2 Transport, lifting and storage ........................................................................17
4.2.1 Transport.....................................................................................................18
4.2.2 Lifting..........................................................................................................18
4.2.3 Storage.......................................................................................................20
5 Installation..................................................................................................21
5.1 Preparation for installation............................................................................21
5.2 Checking the installation conditions...............................................................21
5.3 Additionalttings.........................................................................................22
6 Start-up and operation ................................................................................24
6.1 Start-up.......................................................................................................24
6.1.1 Installing the regulator..................................................................................24
6.1.2 Pipelineushing...........................................................................................25
6.1.3 Pressure test.................................................................................................25
6.2 Adjusting the set point..................................................................................26
7 Maintenance ...............................................................................................27
7.1 Preparation for return shipment.....................................................................28
7.2 Ordering spare parts and operating supplies .................................................29
8 Malfunctions ...............................................................................................29
9 Decommissioning and removal ....................................................................32
9.1 Decommissioning.........................................................................................32
9.2 Disposal......................................................................................................32
10 Annex.........................................................................................................33
10.1 After-sales service........................................................................................33
10.2 Certicates ..................................................................................................33

4 EB 2546-1 EN

EB 2546-1 EN 5
Safety instructions and measures
1 Safety instructions and measures
Intended use
TheSAMSONType36-3Regulatorisasafetyshut-offvalve(SSV)withpressurereducing
valve.
The self-operated regulator is used to control the downstream pressure p2in the pipeline to
the adjusted set point. It controls liquids in process plants and district heating applications.
Theregulatorsaredesignedtooperateunderexactlydenedconditions(e.g.operatingpres-
sure, process medium, temperature). Therefore, operators must ensure that the regulators are
onlyusedinoperatingconditionsthatmeetthespecicationsusedforsizingthedevicesat
the ordering stage. In case operators intend to use the regulators in other applications or
conditionsthanspecied,contactSAMSON.
SAMSON does not assume any liability for damage resulting from the failure to use the de-
vice for its intended purpose or for damage caused by external forces or any other external
factors.
ÎRefertothetechnicaldataandnameplateforlimitsandeldsofapplicationaswellas
possible uses.
Reasonably foreseeable misuse
The regulators are 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accessoriesmountedontheregulator
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
−Changingparts,serviceorrepairworkonTÜV-testedType36-3
Qualications of operating personnel
The regulator 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.Accord-
ing 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appli-
cable standards.

6 EB 2546-1 EN
Safety instructions and measures
Personal protective equipment
Werecommendcheckingthehazardsposedbytheprocessmediumbeingused(e.g.
uGESTIS(CLP)hazardoussubstancedatabase).
ÎProvide protective equipment (e.g. safety gloves, eye protection) appropriate for the pro-
cess medium used.
ÎWear hearing protection when working near the regulator.
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.
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regulator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oper-
ating instructions, especially for installation, start-up and service work.
Wealsorecommendcheckingthehazardsposedbytheprocessmediumbeingused(e.g.
uGESTIS(CLP)hazardoussubstancedatabase).
ÎObservesafetymeasuresforhandlingthedeviceaswellasrepreventionandexplosion
protection measures.
Responsibilities of the operator
The operator is responsible for proper operation and compliance with the safety regulations.
Operators are obliged to provide these mounting and operating instructions as well as the
referenced documents to the operating personnel and to instruct them in proper operation.
Furthermore, the operator must ensure that operating personnel or third persons are not ex-
posed to any danger.

EB 2546-1 EN 7
Safety instructions and measures
Responsibilities of operating personnel
Operating personnel must read and understand these mounting and operating instructions as
wellasthereferenceddocumentsandobservethespeciedhazardstatements,warnings
and caution notes. Furthermore, the operating personnel must be familiar with the applicable
health, safety and accident prevention regulations and comply with them.
Referenced standards and regulations
TheregulatorscomplywiththerequirementsoftheEuropeanPressureEquipmentDirective
2014/68/EU.RegulatorswithaCEmarkinghaveanEUdeclarationofconformity,which
includesinformationabouttheappliedconformityassessmentprocedure.ThisEUdeclaration
ofconformityisincludedintheAnnex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 regulators 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 Di-
rective 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).

8 EB 2546-1 EN
Safety instructions and measures
1.1 Notes on possible severe personal injury
DANGER
!
Risk of bursting in the regulator.
Regulators and pipelines are pressure equipment. Improper opening can lead to com-
ponents bursting.
ÎBeforestartinganyworkontheregulator,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
!
Risk of personal injury due to preloaded springs.
Regulators in combination with preloaded set point springs are under tension. These
regulatorscanbeidentiedbytheredwarninglabelontheactuator'ssetpointsprings.
ÎBefore starting any work on the springs, relieve the compression from the preloaded
springs.
ÎOnly use the SAMSON disassembly tool (1280-4052).
Crush hazard arising from moving parts.
The regulator contains moving parts (actuator and plug stems), which can injure hands
orngersifinsertedintothevalve.
ÎDonotinserthandsorngersbetweenthesetpointspringswhiletheregulatorisin
operation.
ÎBeforeperforminganyworkontheregulator,depressurizetheplant.Disconnector
shut off the external control line.

EB 2546-1 EN 9
Safety instructions and measures
1.2 Notes on possible personal injury
WARNING
!
Damage to health relating to the REACH regulation.
If a SAMSON 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indicat-
ed on the SAMSON delivery note.
ÎInformation on safe use of the part affected,
see uhttp://www.samsongroup.com/en/about-samson/material-compliance/
reach-regulation/
Risk of personal injury due to residual process medium in the regulator.
While working on the regulator, residual process medium can escape and, depending
on its properties, may lead to personal injury, e.g. burns.
ÎIf possible, drain the process medium from all the plant sections concerned and the
regulator.
ÎWear protective clothing, safety gloves and eyewear.
Risk of burn injuries due to hot or cold components and pipelines.
Depending on the process medium, regulator 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.

10 EB 2546-1 EN
Safety instructions and measures
1.3 Notes on possible property damage
NOTICE
!
Risk of regulator damage due to incorrectly attached slings.
ÎDo not attach load-bearing slings to the actuator housing.
Risk of regulator damage due to unsuitable medium properties.
Theregulatorisdesignedforaprocessmediumwithdenedproperties.
ÎOnlyusetheprocessmediumspeciedforsizing.
Risk of regulator damage due to contamination (e.g. solid particles) in the pipeline.
The plant operator is responsible for cleaning the pipelines in the plant.
ÎFlush the pipelines before start-up.
ÎObserve the maximum permissible pressure for regulator and plant.
Risk of regulator damage due to the use of unsuitable lubricants.
The lubricants to be used depend on the regulator material. Unsuitable lubricants may
corrode and damage the surface.
ÎOnly use lubricants approved by SAMSON.
Risk of leakage and regulator damage due to excessively high or low tightening
torques.
Observethespeciedtorquesontighteningregulatorcomponents.Excessivelytightened
torques lead to parts wearing out quicker. Parts that are too loose may cause leakage.
ÎObservethespeciedtighteningtorques.
Risk of regulator damage due to the use of unsuitable tools.
Certain tools are required to work on the regulator.
ÎOnly use tools approved by SAMSON.
SAMSON's After-sales Service can support you concerning lubricant, tightening torques
and tools approved by SAMSON.
Note

EB 2546-1 EN 11
Markings on the device
2 Markings on the device
2.1 Regulator nameplate
2314 5
1110987
6
1Valvetype
2 Model number with index
3CongurationID
4 Order number or date
5 KVScoefcient
6 Set point range
7Valvesize
8 Nominal pressure
9 Perm. differential pressure
10 Perm. temperature
11 Body material
Fig.1: Nameplate
Thenameplateofallsizesisafxedtothebodyange(seeFig.2).
Nameplate position on the body
Fig.2: Nameplate on the body ange

12 EB 2546-1 EN
Design and principle of operation
2.2 Material number
SpecifyingthecongurationID,youcancon-
tactustondoutwhichmaterialisused.The
congurationIDisspeciedonthename-
plate(3,congurationID).Formoredetails
onthenameplate,seesection2.1.
3 Design and principle of oper-
ation
ÎRefertoFig.3
TheType36-3PressureReducingValve
mainly consists of the spring-loaded globe
valve with balanced plug and the actuator
with one operating diaphragm and one
backup diaphragm.
The pressure reducing valve is used to main-
tain the pressure downstream of the valve to
an adjusted set point.
The valve closes when the downstream pres-
sure rises.
Theprocessmediumowsthroughthevalve
between seat (2) and plug (3) in the direc-
tion indicated by the arrow on the body. The
position of the valve plug determines the
owrateand,asaresult,thepressureratio
across the valve. The plug stem is sealed by
a frictionless bellows (8). The downstream
pressure p2to be controlled is transmitted
over the control line (12) to the operating di-
aphragm (11.1) where it is converted into a
positioning force. This force is used to move
the valve plug depending on the force of the
set point springs (7). The spring force is ad-
justable at the set point adjuster (6). The
valves with KVS4andhigherhaveabalanc-
ing bellows (5). The upstream pressure acts
on the outside of the bellows and the down-
stream pressure on the inside of the bellows.
As a result, the forces produced by the up-
stream and downstream pressures acting on
the plug are balanced out.
The regulator is equipped with two indepen-
dent operating diaphragms: one operating
diaphragm (11.1) and a backup diaphragm
(11.2).
As a result, the regulator can continue to
function in the event that the operating dia-
phragm fails. To indicate the diaphragm fail-
ure, a diaphragm rupture indicator is in-
stalled in the intermediate piece (11.4).

EB 2546-1 EN 13
Design and principle of operation
12
p
2
p1
1
2
3
4
5
6
7
8
11.2
11
9
10
11.4
11.3
13
11.1
1Valvebody
2 Seat
3 Plug
4 Plug stem
5 Balancing bellows
6 Set point adjuster
7 Set point springs
8 Bellows seal
9 Nut
10 Crossbeam
11 Actuator housing
11.1 Operating diaphragm
11.2 Backup diaphragm
11.3 Diaphragm rupture
indicator
11.4 Intermediate piece
12 Control line
13 Restriction
Fig.3: Functional diagram
Viewdrawnturned
by 90°

14 EB 2546-1 EN
Design and principle of operation
3.1 Technical data
The regulator's nameplate contains informa-
tion on the regulator version (see sec-
tion2.1).
Process medium and scope of application
TheType36-3SafetyPressureReducing
Valveisdesignedtomaintainpressure
downstream of the regulator to the adjusted
set point district heating systems or large
heating networks.
The regulator is suitable for controlling liq-
uids.
−Liquids up to 150°C
The regulator is open when relieved of pres-
sure. It closes when the downstream pressure
rises above the adjusted set point.
Type test
The device has been typetested as a safety
shut-offvalve(SSV)bytheGermanTechnical
Inspectorate(TÜV)accordingtotherequire-
mentsstipulatedbyAGFW(GermanDistrict
HeatingAssociation).
The test mark is available on request.
Temperature range
TheType36-3Regulatorisdesignedfora
temperaturerangefrom0to+150°C.
Leakage class
The regulator has the leakage class I accord-
ingtoIEC60534-4.
Noise emission
SAMSON is unable to make general state-
ments about noise emission as it depends on
the regulator version, plant facilities and
process medium.
Risk of hearing loss or deafness due to loud
noise.
Wear hearing protection when working near
the regulator.
Dimensions and weights
Table3providesasummaryofthedimen-
sions and weights. The lengths and heights
in the dimensional drawings are shown on
page16onwards.
WARNING
!

EB 2546-1 EN 15
Design and principle of operation
Table1: Technical data · All pressures in bar (gauge)
Valve size DN 15 20 25 32 40 50 65 80 100
KVScoefcient 4.0 6.3 8.0 16.0 20.0 32.0 50.0 80.0
125.0
xFZ value 0.60 0.55 0.50 0.45 0.40 0.35
Pressure rating PN16,25or40
Max. permissible differential
pressure∆p 25bar 20bar 16bar
Overload protection 12 bar (on one side)
Max. permissible
temperature 150°C
Max. permissible ambient
temperature 80°C
Set point ranges bar 2.0 to 4.2 · 2.4 to 6.3 · 6.0 to 10.5
Leakage class according to
IEC60534-4 ≤0.05%ofKVScoefcient
Compliance
Table2: Materials · Material numbers according to DIN EN
Valve
Pressure rating PN16 PN 25 PN 40
Body CastironEN-GJL-250 Spheroidal graphite iron
EN-GJS-400-18-LT Cast steel 1.0619
Seat Stainless steel
PlugwithPTFEsoft
seal Stainless steel
Balancing bellows
and bellows seal Stainless steel
Actuator
Diaphragm cases SheetsteelS235JR(St37-2)
Diaphragm EPDMwithfabricreinforcement

16 EB 2546-1 EN
Design and principle of operation
Dimensional drawings
H
ØD
L
H2
L
M
Fig.4: Dimensions
Table3: Dimensions in mm and weights
Valve size DN 15 20 25 32 40 50 65 80 100
Length L 130 150 160 180 200 230 290 310 350
Height H 415 470 600 615
Height Forged steel H2 53 – 70 – 92 98 – 128 –
Other materials 44 72 98 118
Diaphragm housing ØD 170mm,A=80cm²
Length LM30mm
Weight
WeightforPN161) (approx. kg) 13.0 14.0 14.5 20.0 22.0 25.5 41.5 48.5 57.5
1) +10%forspheroidalgraphiteironEN-GJS-400-18-LT(PN25)andcaststeel1.0619(PN40)

EB 2546-1 EN 17
Measures for preparation before installation
4 Measures for preparation
before installation
After receiving the shipment, proceed as fol-
lows:
1. Check the scope of delivery. Compare
the shipment received with the delivery
note.
2. Check the shipment for transportation
damage. Report any damage to
SAMSON and the forwarding agent
(refer to delivery note).
4.1 Unpacking
Risk of regulator damage due to foreign par-
ticles entering the valve.
The protective caps tted on the regulator's
inlet and outlet prevent foreign particles from
entering the regulator and damaging it.
Do not remove the protective caps until
immediately before installation.
Do not remove the packaging until immedi-
ately before installation.
Proceed as follows to lift and install the regu-
lator:
1. Remove the packaging from the control-
ler.
2. Dispose of the packaging in accordance
with the valid regulations.
NOTICE
!
Note
4.2 Transport, lifting and
storage
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
regulator.
−Refer to Table3 for weights.
Risk of personal injury due to the regulator
tipping.
−Observe the regulator's center of gravity.
−Secure the regulator against tipping over
or turning.
Personnel must be trained to secure, trans-
port and lift the regulator properly.
DANGER
!
WARNING
!
WARNING
!
Note

18 EB 2546-1 EN
Measures for preparation before installation
4.2.1 Transport
The regulator can be transported using lifting
equipment (e.g. crane or forklift).
ÎLeave the regulator in its transport con-
tainer or on the pallet to transport it.
ÎObserve the transport instructions.
Transport instructions
−Protect the regulator against external in-
uences(e.g.impact).
−Do not damage the corrosion protection
(paint, surface coatings). Repair any
damage immediately.
−Protect the regulator against moisture
and dirt.
−Observe the permissible ambient tem-
peratures(seesection3.1).
4.2.2 Lifting
To install a large regulator into the pipeline,
use lifting equipment (e.g. crane or forklift)
to lift it.
Lifting instructions
−Secure slings against slipping.
−Make sure the slings can be removed af-
ter installation.
−Prevent the regulator from tilting or tip-
ping.
−Do not leave loads suspended when in-
terrupting work for longer periods of
time.
−Make sure that the axis of the pipeline is
alwayshorizontalduringliftingandthe
axis of the plug stem is always vertical.

EB 2546-1 EN 19
Measures for preparation before installation
Lifting
1. Attachoneslingtotheangeofthe
body and to the rigging equipment (e.g.
hook)ofthecraneorforklift(seeFig.5).
2. Carefully lift the regulator. Check wheth-
er the lifting equipment and accessories
can bear the weight.
3. Move the regulator at an even pace to
the site of installation.
4. Install the regulator into the pipeline. See
section5.
5. After installation in the pipeline, check
whethertheregulatorangesarebolted
tight.
6. Remove slings.
We recommend using a hook with safety
latch (see Fig.5). The safety latch prevents
the slings from slipping during lifting and
transporting.
Tip Fig.5: Schematic drawing of lifting points on
the regulator

20 EB 2546-1 EN
Measures for preparation before installation
Storage instructions
−Protect the regulator against external in-
uences(e.g.impact).
−Do not damage the corrosion protection
(paint, surface coatings). Repair any
damage immediately.
−Protect the regulator against moisture
and dirt. Store it at a relative humidity of
lessthan75%.Indampspaces,prevent
condensation. If necessary, use a drying
agent or heating.
−Make sure that the ambient air is free of
acids or other corrosive media.
−The permissible storage temperature of
standardregulatorsis–20to+65°C(–4
to+149°F).
−Do not place any objects on the
regulator.
Special storage instructions for elastomers
Elastomer,e.g.actuatordiaphragm
−We recommend a storage temperature of
15°C(59°F)forelastomers.
SAMSON's After-sales Service can provide
more detailed storage instructions on re-
quest.
Tip
Standard mounting position
Alternative mounting position
forliquidsupto80°C
Fig.6: Mounting position
4.2.3 Storage
Risk of regulator damage due to improper
storage.
−Observe storage instructions.
−Avoid long storage times.
−Contact SAMSON in case of different stor-
age conditions or long storage periods.
We recommend regularly checking the regu-
lator and the prevailing storage conditions
during long storage periods.
NOTICE
!
Note