Samson 3248-1 Service manual

Pneumatic Control Valve
Type 3248-1 and Type 3248-7
Mounting and
Operating Instructions
EB 8093 EN
Edition September 2008
Fig. 1 · Type 3248 as globe-pattern valve and angle-pattern valve, both fitted with Type 3277 Pneumatic Actuator

Contents Page
1 Design and principle of operation . . . . . . . . . . . . . . . . . . . 4
2 Assembling and adjusting valve and actuator. . . . . . . . . . . . . . . 6
2.1 Option to pretension the springs for actuator version
"Actuator stem extends" . . . . . . . . . . . . . . . . . . . . . . . . 7
2.2 Valve and actuator that have different rated travels . . . . . . . . . . . 7
3 Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
3.1 Mounting position . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
3.2 Signal pressure line. . . . . . . . . . . . . . . . . . . . . . . . . . . 8
4 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
5 Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
5.1 Replacing packing, seat, and plug . . . . . . . . . . . . . . . . . . . 9
6 Version with split plug stem extension. . . . . . . . . . . . . . . . . 11
7 Customer inquiries . . . . . . . . . . . . . . . . . . . . . . . . . . 13
2EB 8093 EN
Contents
Note:
Non-electrical actuators and valves do not have their own potential ignition source
according to the risk assessment in the rare incident of an operating fault, corresponding to
EN 13463-1: 2001 paragraph 5.2, and therefore do not fall within the scope of the
European Directive 94/9/EC.
Refer to paragraph 6.3 of EN 60079-14:1977 VDE 0165 Part 1 concerning connection to
equipotential bonding system.

EB 8093 EN 3
Safety instructions
General safety instructions
4
The control valve may only be mounted, started up or serviced by fully
trained and qualified personnel, observing the accepted industry codes and
practices. Make sure employees or third persons are not exposed to any
danger. All safety instructions and warnings in these mounting and
operating instructions, particularly those concerning assembly, start-up and
maintenance, must be observed.
4
The control valves fulfill the requirements of the European Pressure
Equipment Directive 97/23/EC. Valves with a CE marking have a
declaration of conformity that includes information about the applied
conformity assessment procedure.
The corresponding declaration of conformity can be viewed and
downloaded on the Internet at http://www.samson.de.
4
For appropriate operation, make sure that the control valve is only used in
areas where the operating pressure and temperatures do not exceed the
operating values which are based on the valve sizing data submitted in the
order. The manufacturer does not assume any responsibility for damage
caused by external forces or any other external influence!
4
Any hazards which could be caused in the control valve by the process
medium, operating pressure, signal pressure or by moving parts are to be
prevented by means of the appropriate measures.
4
Proper shipping and appropriate storage of the control valve are assumed.
Caution!
4
For installation and maintenance work on the valve, make sure the relevant
section of the pipeline is depressurized and, depending on the process
medium, drained as well. If necessary, allow the control valve to cool down
or warm up to reach ambient temperature prior to starting any work on the
valve.
4
Prior to performing any work on the valve, make sure the supply air and
control signal are disconnected or blocked to prevent any hazards that
could be caused by moving parts.
4
Special care is needed for pneumatic control valves when the actuator
springs are pretensioned. These actuators are labeled correspondingly and
can also be identified by three long bolts protruding from the bottom of the
actuator. Prior to starting any work on the control valve, relieve the
compression from the pretensioned springs.

1 Design and principle of
operation
The Type 3248 Cryogenic Valve can be
combined with either a Type 3271 or a
Type 3277 Pneumatic Actuator with integral
positioner attachment.
The globe-pattern or angle-pattern valve
body is designed for welding in vacuum-in-
sulated pipelines or for installation in
cold-box applications.
The cryogenic extension bonnet consists of a
metal bellows located directly above the
valve body and the insulating section above
the bellows seal.
The test connection (4.4) allows the pressure
to be monitored in order to check for leak-
age of the metal bellows.
The process medium flows through the valve
in the direction indicated by the arrow. The
position of the plug (3) is determined by
changes in the signal pressure acting on the
actuator diaphragm.
The stem connector (7) connects the plug
stem (6) with attached plug (3) and actuator
stem (8.1).
The plug stem is sealed by the metal bellows
and the backup stuffing box (4) with
spring-loaded PTFE-carbon V-ring packing
(4.2).
Fail-safe position:
Depending on how the springs (8.3) are ar-
ranged in the actuator, the control valve as-
sumes two different fail-safe positions:
Actuator stem extends:
When the pressure is relieved or the supply
air fails, the actuator springs move the actu-
ator stem downwards and close the valve.
Actuator stem retracts:
When the pressure is relieved or the supply
air fails, the actuator springs move the actu-
ator stem upwards and open the valve.
4EB 8093 EN
Design and principle of operation
Legend to Fig. 2
1 Valve body
1.1 Cryogenic extension bonnet
1.3 Nuts
2 Seat
3 Plug
4.1 Spring
4.2 Packing
4.3 Washer
4.4 Test connection
5 Valve bonnet
5.1 Guide bushing
5.2 Threaded bushing
5.3 Nuts
5.4 Travel scale indicator
5.5 Seal
6 Plug stem
6.1 Stem connector nut
6.2 Lock nut
6.3 Plug stem extension with metal bellows
6.3a and 6.3b with split extension bonnet
6.4 Bellows nut
6.5 Bellows flange
6.6 Guide bushing
(not with NPS 4 and 6/Class 150 - 300,
version with split plug stem extension)
6.7 Nut(s)
6.8 Washers
7 Stem connector
8 Actuator
8.1 Actuator stem
8.2 Annular nut
8.3 Springs
8.4 Rollng diaphragm
9 Loading pressure connection
10 Venting plug

EB 8093 EN 5
Design and principle of operation
Fig. 2 · Sectional drawings
Top section (6.3a)
Nut
Bottom section (6.3b)
Version with split
plug stem extension,
refer to section 6
Type 3271 Actuator Type 3277 Actuator
Globe valve
Aluminum
angle valve

2 Assembling and adjusting
valve and actuator
If the valve and actuator have not been pre-
assembled by the manufacturer or in the
case that the original actuator attached to
the valve is to be replaced by another actua-
tor of a different type or size, proceed as
follows:
Removing a mounted actuator
Note!
For actuators with fail-safe action "Actuator
stem extends" and especially actuators with
pretensioned springs, apply a pressure
slightly higher than the lower signal pressure
range (see actuator nameplate) to the
loading pressure connection on the bottom
diaphragm chamber, before loosening the
annular nut (8.2).
4Remove clamps of the stem connector (7)
between the actuator and plug stem ex-
tension and unscrew annular nut (8.2).
4Lift the actuator off the valve.
Mounting the actuator
1. Loosen the lock nut (6.2) and stem con-
nector nut (6.1) on the valve. Firmly
press the plug with the plug stem into the
seat. Then thread down the lock nut and
stem connector nut.
2. Remove clamps of the stem connector (7)
and annular nut (8.2) on the actuator
(8).
3. Slide the annular nut over the plug stem
extension.
4. Place the actuator on the valve bonnet
(5) and screw tight using the annular nut
(8.2).
5. Read the nameplate on the actuator to
determine which bench range (signal
range with pretensioned springs) and
which operating mode of the actuator
are used.
The operating mode (fail-safe action) "Actu-
ator stem extends" or "Actuator stem re-
tracts" is indicated on the nameplate by FA
or FE on the Type 3271 Actuator and by the
appropriate symbol on the Type 3277 Actu-
ator.
The lower bench range corresponds to the
lower signal pressure range to be adjusted;
the upper bench range corresponds to the
upper signal pressure range.
6. For actuators with fail-safe action "Actu-
ator stem extends", apply the pressure
corresponding to the lower signal pres-
sure range (e.g. 0.2 bar) to the loading
pressure connection on the bottom dia-
phragm chamber.
For actuators with fail-safe action "Actu-
ator stem retracts", apply the pressure
corresponding to the upper signal pres-
sure range (e.g. 1 bar) to the loading
pressure connection on the top dia-
phragm chamber.
7. Manually turn the stem connector nut
(6.1) until it touches the actuator stem
(8.1) and then turn it a further 1/4 turn.
Screw tight the lock nut (6.2) while hold-
ing the stem connector nut stationary to
6EB 8093 EN
Assembling and adjusting valve and actuator

ensure that the plug stem extension (6.3)
with the metal bellows is not twisted.
8. Position clamps of the stem connector (7)
and fasten
9. Align travel indicator scale (5.4) with tip
of the stem connector; for actuators with
"Actuator stem extends" align it with
lower marking (valve closed) and for ac-
tuators with "Actuator stem retracts"
align it with top marking (valve open).
2.1 Option to pretension the
springs for actuator version
"Actuator stem extends"
To achieve a greater thrust, the springs of
actuators can be pretensioned by 12.5 %
(240 cm²), by 25 % (350 and 700 cm²) or
by 75 % (700 cm²) of their travel or their
bench range.
If, with a bench range of 0.2 to 1 bar, the
springs are to be pretensioned by 0.1 bar,
for example, the bench range is shifted by
0.1 bar to 0.3 bar.
When adjusting the valve, a signal pressure
of 0.3 bar is to be set as the lower signal
pressure range.
The new bench range of 0.3 to 1.1 bar must
be marked on the nameplate as bench
range with pretensioned springs.
2.2 Valve and actuator that have
different rated travels
Actuators with springs that have already
been pretensioned by the manufacturer
without attachment to a valve are marked by
an appropriate label.
In addition, such actuators can be identified
by three bolts and nuts protruding from the
bottom diaphragm case which allow the
compression of the springs to be unloaded
evenly before removing the actuator from
the valve.
EB 8093 EN 7
Assembling and adjusting valve and actuator

3 Installation
3.1 Mounting position
The valve can be mounted in any position.
It must be installed free of tension.
If necessary, supports can be mounted on
the pipelines near the connections.
Caution!
Prior to weld the valve body into the
pipeline, apply the loading pressure for
valves with fail-safe action “Actuator stem
extends” (valve closed), to move the valve
plug out of the seat. This prevents the trim
from being damaged by excessive high
temperatures.
Note:
Remove the stopper from the test connection
(4.4) to allow the metal bellows (6.3) to be
monitored for leakage.
3.2 Signal pressure line
Connect the signal pressure line for valves
with actuator version "Actuator stem ex-
tends" to the loading pressure connection on
the bottom diaphragm case, and for valves
with actuators "Actuator stem retracts" to the
loading pressure connection on the top dia-
phragm case.
The lower connection of Type 3277 Actuator
is located on the yoke of the bottom dia-
phragm case.
4 Operation
To reverse the direction of action, refer to
Mounting and Operating Instructions of the
respective pneumatic actuator.
EB 8310 EN for Type 3271 and
EB 8311 EN for Type 3277.
5 Maintenance
If leakage occurs, this could be caused by a
damaged metal bellows (6.3) or a defective
packing (4.2).
If the valve does not seal properly, the tight
shut-off may be impeded by dirt or other im-
purities caught between the seat and plug,
or by damaged facings.
Remove the parts, clean them thoroughly
and replace them with new ones, if neces-
sary.
Before servicing or disassembling the
control valve, depressurize the con-
cerned section of the plant and drain
it.
Wait until the medium has reached
ambient temperature, if necessary.
As valves are not free of cavities,
there might still be residual medium
in the valve. We recommend remov-
ing the valve from the pipeline or re-
move the entire valve assembly when
the valve is welded in the pipeline.
On performing any work on the
valve body, first shut off the supply
pressure, disconnect the supply pres-
sure line and remove the actuator.
8EB 8093 EN
Installation

Note:
Seat wrenches can be ordered using the
following order numbers:
For DN 15 to 150: Complete set 1280-3047
For DN 15 and 25: Single set 1280-3073
5.1 Replacing packing, seat, and
plug
Removing the actuator
Prior to performing any work on the valve
body, remove the actuator first.
Note!
For actuators with fail-safe action "Actuator
stem extends" and especially actuators with
pretensioned springs, apply a pressure
slightly higher than the lower signal pressure
range (see actuator nameplate) to the
loading pressure connection on the bottom
diaphragm chamber, before loosening the
annular nut (8.2).
1. Remove clamps of the stem connector (7)
between actuator stem and plug stem
and unscrew annular nut (8.2).
2. Lift the actuator off the valve.
Caution!
To avoid damaging the metal bellows, make
sure that no torque is transmitted to the
bellows welded to the plug stem extension
(6.3, 6.3 b).
Packing
1. Place a wrench at the stem connector nut
(6.1) to hold it stationary and loosen the
lock nut (6.2). Unscrew stem connector
nut and lock nut.
2. Unthread guide bushing (5.2) to relieve
the tension from the packing.
3. Unthread the nuts (5.3) at the valve bon-
net. Lift valve bonnet (5) upwards off the
flanged section of the cryogenic exten-
sion bonnet (1.1) .
4. Unthread threaded bushing (5.2) and
use a suitable tool to remove the pack-
ing rings (4.2), washer (4.3), and spring
(4.1).
Replace damaged parts with new ones.
Carefully clean the packing chamber.
EB 8093 EN 9
Maintenance
Fig. 3 · Sectional drawing

Plug:
Caution! Do not twist the bellows!
1. Use SAMSON socket wrench to unscrew
the bellows nut (6.4). Pull plug stem ex-
tension together with the bellows seal,
guide bushing (6.6), and the plug stem
and plug out of the cryogenic extension
bonnet.
2. Used a suitable tool to clamp the cryo-
genic extension bonnet tightly.
3. Unthread the plug out of the extension.
4. Loosen nut (6.7). Unscrew guide bushing
(6.6). In the case of large nominal sizes,
unscrew second nut and remove guide
bushing.
Note! There is no guide bushing (6.6) in
valve sizes NPS 4 and 6/Class 150 - 300,
version with split plug stem extension.
5. Apply lubricant (order no. 8150-0116)
to the plug stem thread of the new or
original plug that has been machined.
6. Screw guide bushing (6.6) onto the plug
stem extension as far as it will go. Lock
into position with the nut (6.7) or slide
on the guide bush and fasten with two
nuts.
7. Check that both washers (6.8) are still in
the plug stem extension. Screw the plug
stem tightly into the plug stem extension.
Tightening torque: 50 Nm with DN 25
to 80 and 80 Nm with DN 100 to 150.
Seat:
If the seat must also be replaced, proceed as
follows:
8. Use a SAMSON seat wrench to unscrew
the seat (2) out of the valve body.
9. Apply lubricant (order no. 8150-0116)
to the seat thread of the new seat and
screw in tightly observing the tightening
torques in Table 1.
Assembly:
1. Slide plug stem extension together with
guide bushing and plug into the body.
2. Insert bellows nut (6.4) and screw tight
(observing tightening torques in the table
below). Make sure that no torque is
transmitted to the bellows.
10 EB 8093 EN
Maintenance
Table 1 Tightening torque Nm or steel and aluminum version
Nominal size Seat (2) Bellows nut
(6.4) Body nut (5.3)
Body nut (1.3)
only with aluminum
angle valves
DN NPS Red. seat bore Max. seat bore
15 to 25 ½ to 1 150 150 200 30 20
32 to 50 1½ to 2 450 400 1000 60 30
65 to 80 2½ to 3 900 850 2000 100 60
100 4 1400 1050 3000 100 100
150 6 2300 2100 3000 100 100

3. Insert new seal (5.5) into the flanged
section. Slide valve bonnet over the plug
stem extension and place it on the
flanged section.
4. Thread on nut (5.3) and screw tight, ob-
serving the tightening torques in Table 1.
5. Apply lubricant (order no. 8150-0116)
to packing parts and threaded bushing
(5.2).
Slide spring (4.1), washer (4.3), and
new packing rings (4.2) over the plug
stem extension into the packing cham-
ber.
Put on threaded bushing (5.2) and
tighten it as far as it will go.
6. Screw the lock nut (6.2) and nut (6.1)
loosely onto the plug stem extension
(6.3).
7. Mount actuator and adjust the lower or
upper bench range as described in sec-
tion 2.
6 Version with split plug stem
extension
To keep the overall height of the valve as
small as possible for transportation purposes
in cold-box installations, the actuator and
valve bonnet must be removed from the
flanged section of the cryogenic extension
bonnet and protected by a protective cap
and a stopper.
If these measures have not been undertaken
prior to delivery, proceed as follows:
The special tool (order no. 1280-3031,
Fig. 4) is required for assembly and reas-
sembly. Only the use of this tool guarantees
that the metal bellows will not be damaged.
EB 8093 EN 11
Version with split plug stem extension
Fig. 4 · Mounting the protective cap
5.3 Nut
6.3b Plug stem extension
(bottom section)
20 Nut
Special tool
with 17 and 24 mm
socket wrench
22 Nut
23 Protective cap
24 Seal
25 Stopper

Disassembly:
Important!
For actuators with fail-safe action "Actuator
stem extends" and especially actuators with
pretensioned springs, apply a pressure be-
forehand to retract the actuator stem slightly.
1. Remove clamps of the stem connector (7)
between actuator stem and plug stem
and unscrew annular nut (8.2).
2. Lift the actuator off the valve.
3. Place a wrench at the stem connector nut
(6.1) to hold it stationary and loosen the
lock nut (6.2). Unscrew stem connector
nut and lock nut from the plug stem ex-
tension (6.3a).
Caution! The plug stem extension may not
be twisted at all, otherwise the metal bellows
could be damaged.
4. Unthread guide bushing (5.2) to relieve
the tension from the packing (4.2).
5. Unthread nuts (5.3) at the valve bonnet.
Lift valve bonnet (5) carefully upwards
off the flange of the cryogenic extension
bonnet (1.1).
6. Place the special tool with 24 mm socket
wrench over the plug stem extension
(6.3b) onto the nut (20) in such a way
that the labeling "disassem-
ble/demontieren" faces upwards. (As
the needle bearing of the tool can only
be turned in one direction, it must be
placed turned by 180° as required for
assembly or disassembly.)
Insert 17 mm socket wrench and un-
screw the top section of the plug stem
extension (6.3a) with socket wrench.
7. In case of DN 100 and 150 (NPS 4 and
6), unscrew nut (20). In case of DN 25
to 80 (NPS 1 to 3) the nut remains on
the plug stem extension.
8. Insert seal (24) and fit on protective cap
(23).
9. Apply lubricant (order no. 8150-0116)
to the protruding thread of the plug stem
extension to prevent dirt and moisture
from entering the plug stem extension.
10.Screw on nut (22) and hand tighten to
extract the plug stem extension to the di-
mension
h (Table 2). Do not tighten
more than 10 Nm, otherwise the metal
bellows will be damaged.
11.Tighten nut (5.3) (tightening torque in
Table 2).
12.Insert stopper (25).
12 EB 8093 EN
Version with split plug stem extension
Table 2 Version with split plug stem extension
Nominal size Tightening torque Nm Dimension h
Nut (22) Nut (5.3) Plug stem extension (6a) mm/inch
DN NPS Class 150/300/600
15 to 80 1 to 3 Max. 10
(hand tight)
30 50 15/ 0.6
100/150 4 to 6 50 80 26/1.0

Assembly
After transportation, reassemble the valve as
follows:
Observe tightening torques in Table 1!
1. Remove stopper (25) and clean inside
the protective cap.
2. Unthread nut (22) with 24 mm socket
wrench.
3. Loosen nut (5.3) and remove protective
cap (23).
4. Place the special tool with 24 mm socket
wrench in such a way that the labeling
"assemble/montieren" faces upwards. In
case of DN 100 and 150 (NPS 4 and 6)
valves, screw on nut (20) as far as it will
go by hand.
5. Screw top section of the plug stem exten-
sion (6.3a) onto thread of the lower sec-
tion (6.3b) by hand.
6. Insert 17 mm socket wrench and tighten
top section of the plug stem extension
(6.3a) with the socket wrench, observing
the tightening torques in Table 2.
7. Insert seal (5.5) into flanged section.
Slide valve bonnet carefully over the
plug stem extension (6.3a) to ensure that
the packing does not get damaged and
place it on the flanged section.
8. Screw on nut (5.3) and tighten.
9. Tighten guide bushing (5.2) as far as it
will go.
10.Thread lock nut (6.2) and nut (6.1)
loosely onto the plug stem extension
(6.3a).
11.Mount actuator and adjust the lower or
upper bench range as described in sec-
tion 2.
7 Customer inquiries
Please submit the following details:
4Type designation and order number (on
nameplate)
4Serial number, nominal size and version
of the valve
4Pressure and temperature of the process
medium
4Flow rate in m³/h
4Bench range (spring range) (e.g. 0.2 to
1 bar) of the actuator
4Installation drawing
Dimensions
Refer to the Data Sheet T 8093 EN for the
dimensions and weights of the various valve
versions.
EB 8093 EN 13
Customer inquiries

14 EB 8093 EN

EB 8093 EN 15

SAMSON AG · MESS- UND REGELTECHNIK
Weismüllerstraße 3 · 60314 Frankfurt am Main · Germany
Phone: [phone] · Fax: [phone]
Internet: http://www.samson.de EB 8093 EN
S/Z 2008-09