Samson 3241 Service manual
Mounting and
Operating Instructions
EB 8012 EN
Translation of original instructions
Edition March 2016
Type3241 Valve with Type3271 Actuator (left) and Type3277 Actuator (right)
Type 3241 Valve
In combination with an actuator,
e.g. a SAMSON Type3271 or Type3277 Pneumatic Actuator
ANSI and JIS version
Denition of signal words
DANGER!
Hazardous situations which, if not
avoided, will result in death or seri-
ous injury
WARNING!
Hazardous situations which, if not
avoided, could result in death or seri-
ous injury
NOTICE
Property damage message or mal-
function
Note:
Additional information
Tip:
Recommended action
2 EB 8012 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
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
(www.samson.de) > Product documentation. You can enter the document
number or type number in the [Find:] eld to look for a document.
Contents
EB 8012 EN 3
1 Safety instructions and measures ...................................................................5
1.1 Notes on possible severe personal injury .........................................................7
1.2 Notes on possible personal injury ...................................................................8
1.3 Notes on possible property damage................................................................9
2 Markings on the control valve......................................................................12
2.1 Valve nameplate ..........................................................................................12
2.2 Actuator nameplate......................................................................................13
2.3 Material number..........................................................................................13
3 Design and principle of operation ................................................................14
3.1 Fail-safe positions ........................................................................................16
3.2 Versions ......................................................................................................16
3.3 Technical data .............................................................................................17
4 Preparation.................................................................................................24
4.1 Unpacking ..................................................................................................24
4.2 Transporting and lifting ................................................................................24
4.2.1 Transporting ................................................................................................25
4.2.2 Lifting..........................................................................................................25
4.3 Storage.......................................................................................................28
4.4 Preparation for installation............................................................................29
5 Mounting and start-up.................................................................................30
5.1 Mounting the actuator onto the valve.............................................................30
5.2 Installing the valve into the pipeline ...............................................................31
5.2.1 Checking the installation conditions...............................................................31
5.2.2 Additional ttings.........................................................................................33
5.2.3 Installing the control valve.............................................................................33
5.3 Quick check ................................................................................................34
6 Operation...................................................................................................36
6.1 Working in manual mode.............................................................................36
4 EB 8012 EN
Contents
7 Maintenance ...............................................................................................38
7.1 Replacing the gasket ....................................................................................39
7.1.1 Standard version..........................................................................................39
7.1.2 Version with insulating section or bellows seal................................................41
7.2 Replacing the packing..................................................................................41
7.2.1 Standard version..........................................................................................41
7.2.2 Version with insulating section.......................................................................42
7.3 Replacing the seat and plug..........................................................................44
7.3.1 Standard version..........................................................................................44
7.3.2 Version with insulating section.......................................................................46
7.4 Preparation for return shipment.....................................................................47
7.5 Ordering spare parts and operating supplies .................................................47
8 Malfunctions ...............................................................................................48
8.1 Troubleshooting ...........................................................................................48
8.2 Emergency action ........................................................................................49
9 Decommissioning and disassembly ..............................................................50
9.1 Decommissioning.........................................................................................50
9.2 Removing the valve from the pipeline.............................................................50
9.3 Removing the actuator from the valve ............................................................51
9.4 Disposal......................................................................................................51
10 Appendix....................................................................................................52
10.1 After-sales service........................................................................................52
10.2 Certicates ..................................................................................................53
10.3 Spare parts .................................................................................................59
EB 8012 EN 5
Safety instructions and measures
1 Safety instructions and measures
Intended use
The SAMSON Type3241 Globe Valve in combination with an actuator (e.g. Type3271 or
Type3277 Pneumatic Actuator) is designed to regulate the ow rate, pressure or temperature
of liquids, gases or vapors. The valve with its actuator is designed to operate under exactly
dened conditions (e.g. operating pressure, process medium, temperature). Therefore, opera-
tors must ensure that the control valve is only used in applications that meet the specications
used for sizing the valve at the ordering stage. In case operators intend to use the control
valve in other applications or conditions than specied, 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 dened during sizing and in the technical data
−Use outside the limits dened 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
Qualications of operating personnel
The control valve must be mounted, started up, serviced, and repaired by fully trained and
qualied 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 8012 EN
Safety instructions and 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
−Wear hearing protection when working near the valve.
ÎCheck with the plant operator for details on further protective equipment.
Revisions and other modications
Revisions, conversions or other modications to the product are not authorized by SAMSON.
They are performed at the user's own risk and may lead to safety hazards, for example. Fur-
thermore, the product may no longer meet the requirements for its intended use.
Safety devices
Upon supply air or control signal failure, the valve moves to its fail-safe position (see sec-
tion3.1). The fail-safe action of the actuator is the same as its direction of action and is spec-
ied 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 specied hazard statements, warning, and caution notes. Furthermore, the oper-
ating personnel must be familiar with the applicable health, safety and accident prevention
regulations and comply with them.
EB 8012 EN 7
Safety instructions and measures
Referenced standards and regulations
The control valves comply with the requirements of the European Pressure Equipment Direc-
tive 97/23/EC. Valves with a CE marking have a declaration of conformity which includes
information about the applied conformity assessment procedure. This declaration of confor-
mity is included in the Appendix of these instructions (see section10.2).
According to the ignition risk assessment performed in accordance with EN13463-1:2009,
section 5.2, the non-electrical control valves 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
Directive 94/9/EC.
ÎFor connection to the equipotential bonding system, observe the requirements specied in
section 6.3 of EN60079-14:2014-10 (VDE0165 Part 1).
Referenced documentation
The following documents apply in addition to these mounting and operating instructions:
−Mounting and operating instructions for mounted actuator, e.g. uEB8310-X for
Type3271 and Type3277 Actuators
−Mounting and operating instructions for mounted valve accessories (positioner, solenoid
valve etc.)
−uAB0100 for tools and lubricant
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
concerned and the valve.
ÎDrain the process medium from all the plant sections concerned as well as the
valve.
ÎWear personal protective equipment.
8 EB 8012 EN
Safety instructions and measures
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 in-
jure hands or ngers if inserted into the valve.
ÎDo not insert hands or nger 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 the 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 silencers and vent plugs.
ÎWear eye protection when working in close proximity to the control valve.
Risk of personal injury due to preloaded springs.
Valves in combination with pneumatic actuators with preloaded springs are un-
der tension. These control valves with SAMSON pneumatic actuators can be
identied 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).
Risk of personal injury due to residual process medium in the valve.
While working on the valve, residual process medium can escape and, depend-
ing 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.
EB 8012 EN 9
Safety instructions and measures
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 gloves.
1.3 Notes on possible property damage
NOTICE
Risk of valve damage due to contamination (e.g. solid particles) in the pipe-
line.
The plant engineering company is responsible for cleaning the pipelines in the
plant.
ÎFlush the pipelines before start-up.
ÎObserve the maximum permissible pressure for valve and plant.
Risk of valve damage due to unsuitable medium properties.
The valve is designed for a process medium with dened properties.
ÎOnly use the process medium specied for sizing the valve.
Risk of leakage and valve damage due to excessively high or low tightening
torques.
Observe the specied torques on tightening control valve components. Excessive-
ly tightened torques lead to parts wearing out quicker. Parts that are too loose
may cause leakage.
ÎObserve the specied tightening torques (uAB0100).
10 EB 8012 EN
Safety instructions and measures
NOTICE
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 (uAB0100).
Risk of valve damage due to the use of unsuitable lubricants.
The lubricants to be used depend on the valve material. Unsuitable lubricants
may corrode and damage the valve surface.
ÎOnly use lubricants approved by SAMSON (uAB0100).
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