Samson 3259 Setup guide

Translation of original instructions

EB 8059 EN

Edition December 2017

Type 3259 Valve

In combination with an actuator,

e.g. a SAMSON Type3271 or Type3277 Pneumatic 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.

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 8059 EN

Contents

EB 8059 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................................................................9

2 Markings on the device ...............................................................................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 ........................................................................................14

3.2 Versions ......................................................................................................16

3.3 Technical data .............................................................................................16

4 Measures for preparation............................................................................20

4.1 Unpacking ..................................................................................................20

4.2 Transporting and lifting ................................................................................20

4.2.1 Transporting ................................................................................................21

4.2.2 Lifting..........................................................................................................22

4.3 Storage.......................................................................................................25

4.4 Preparation for installation............................................................................25

5 Mounting and start-up.................................................................................27

5.1 Mounting the actuator onto the valve.............................................................27

5.2 Installing the valve into the pipeline ...............................................................28

5.2.1 Checking the installation conditions...............................................................28

5.2.2 Additional ttings.........................................................................................29

5.2.3 Installing the control valve.............................................................................29

5.3 Quick check ................................................................................................30

6 Operation...................................................................................................32

6.1 Working in manual mode.............................................................................32

Contents

4 EB 8059 EN

7 Servicing.....................................................................................................34

7.1 Preparing the valve for servicing ...................................................................35

7.2 Replacing the body gasket............................................................................35

7.2.1 Standard version..........................................................................................35

7.2.2 Version with insulating section.......................................................................37

7.2.3 Version with bellows seal..............................................................................37

7.3 Replacing the packing..................................................................................38

7.3.1 Standard version..........................................................................................38

7.3.2 Version with insulating section.......................................................................40

7.4 Replacing the seat and plug..........................................................................41

7.4.1 Standard version..........................................................................................41

7.4.2 Version with insulating section.......................................................................43

7.5 Preparation for return shipment.....................................................................44

7.6 Ordering spare parts and operating supplies .................................................44

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 ............................................................48

9.4 Disposal......................................................................................................48

10 Annex.........................................................................................................49

10.1 After-sales service........................................................................................49

10.2 Certicates ..................................................................................................49

10.3 Spare parts .................................................................................................52

EB 8059 EN 5

Safety instructions and measures

1 Safety instructions and measures

Intended use

The SAMSON Type3259 Angle Valve in combination with an actuator (e.g. Type3271 or

Type3277 Pneumatic Actuator) is designed to regulate the ow rate, pressure or temperature

of liquids, gases or vapors in industrial high-pressure plants according to the IG standard.

The valve with its actuator is designed to operate under exactly dened conditions (e.g.

operating pressure, process medium, temperature). Therefore, operators must ensure that the

control 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

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 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 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 8059 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 valve.

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 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 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 8059 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 control valves comply with the requirements of the European Pressure Equipment Direc-

tive 2014/68/EU. Valves 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 Appendix 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 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 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).

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8310-X for

Type3271 and Type3277 Actuators

−Mounting and operating instructions for mounted valve accessories (positioner, solenoid

valve etc.)

−uAB0100 for tools, tightening torques and lubricant

8 EB 8059 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. Improper opening can lead to valve

components bursting.

ÎBefore starting any work on the valve, 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

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 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.

EB 8059 EN 9

Safety instructions and measures

WARNING

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 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 concerned and the

valve.

ÎWear protective clothing, safety 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 safety gloves.

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.

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 dened properties.

ÎOnly use the process medium specied for sizing.

10 EB 8059 EN

Safety instructions and measures

NOTICE

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

tightened torques lead to parts wearing out quicker. Parts that are too loose may cause

leakage.

ÎObserve the specied tightening torques (uAB0100).

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 (uAB0100).

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 (uAB0100).

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