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Samson 3251-E, Mounting And Operating Instructions

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Samson 3251-E Mounting And Operating Instructions Download Page 76

9-18 

 

EB 8052-E EN

Servicing and conversion

9.4.3  Replacing the trim

Risk of damage to the facing of the seat 

and plug due to incorrect servicing.

 

Î

Always replace both the seat and plug.

We recommend using new packing parts 
and gaskets on replacing the trim.

a)  Removing the (clamped-in) 

seat and plug

Standard and HT packing

1. 

Loosen threaded bushing (8).

2. 

Undo the body nuts (14) gradually in a 

crisscross pattern.

3. 

Valve versions without anti-rotation fix

-

ture:

 ensure that the stem connector nut 

(9) is still fastened tight to the plug stem 
(5.1).

Valve versions with anti-rotation fixture:

 

ensure that the clamps (301) are still fas-
tened tight to the plug stem (5.1).

4.  Lift the valve bonnet (2) including yoke 

(60), plug (5) and plug stem (5.1) up-

wards off the body (1) and set it aside.

5. 

Valve versions without anti-rotation fix

-

ture:

 unscrew the stem connector nut (9) 

and lock nut (10) from the plug stem 
(5.1).

Valve versions with anti-rotation fixture:

 

undo the screws (303) and remove the 
clamps (301) of the anti-rotation fixture. 
Set aside clamps (301), screws (303), 
washers (304) and stem (9).

6.  Unscrew castellated nut (92) and lift the 

yoke (60) off the valve bonnet (2).

7.  Unscrew the threaded bushing (8).
8.  Pull plug stem (5.1) out of the valve bon-

net (2).

9. 

Pull the entire packing out of the packing 
chamber using a suitable tool.

10. 

Clean the packing chamber thoroughly.

11. 

Remove spiral gaskets (17, 126) from the 
body (1) and valve bonnet (2).

12. 

Remove the seat retainer (124) from the 
body (1). For versions ≥NPS 6, a special 
SAMSON tool is available (

u

 AB 0100).

13. Remove seat (4) and spiral gasket (127) 

from the body (1).

LLF 20 packing

1. 

Undo the body nuts (14) gradually in a 

crisscross pattern.

2. 

Valve versions without anti-rotation fix

-

ture:

 ensure that the stem connector nut 

(9) is still fastened tight to the plug stem 
(5.1).

Valve versions with anti-rotation fixture:

 

ensure that the clamps (301) are still fas-
tened tight to the plug stem (5.1).

3.  Lift the valve bonnet (2) including yoke 

(60), plug (5) and plug stem (5.1) up-

wards off the body (1) and set it aside.

NOTICE

!

NOTICE

!

Tip

Summary of Contents for 3251-E

Page 1: ...riginal instructions EB 8052 E EN Edition January 2021 Type 3251 E Valve ANSI version In combination with an actuator e g a Type 3271 or Type 3277 Pneumatic Actuator Type 3251 E Valve with Type 3277 Pneumatic Actuator ...

Page 2: ... Î If you have any questions about these instructions contact SAMSON s After sales Service aftersalesservice samsongroup com Documents relating to the device such as the mounting and operating instructions are available on our website at www samsongroup com Service Support Downloads Documentation Definition of signal words Hazardous situations which if not avoided will result in death or serious i...

Page 3: ...Accessories 3 5 3 4 Additional fittings 3 5 3 5 Valve accessories 3 6 3 6 Technical data 3 6 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 3 4 4 Storing the valve 4 4 5 Installation 5 1 5 1 Installation conditions 5 1 5 2 P...

Page 4: ...ing the gaskets 9 10 a Version with clamped in seat and plug 9 10 b Version with screwed in seat and plug 9 11 c Version with cage and piston 9 13 9 4 2 Replacing the packing 9 13 a Standard and HT packing 9 13 b LLF 20 packing 9 15 9 4 3 Replacing the trim 9 18 a Removing the clamped in seat and plug 9 18 b Removing the screwed in seat and plug 9 19 c Removing the cage and piston 9 21 d Installin...

Page 5: ...52 E EN 12 Repairs 12 1 12 1 Returning devices to SAMSON 12 1 13 Disposal 13 1 14 Certificates 14 1 15 Annex 15 1 15 1 Tightening torques lubricants and tools 15 1 15 2 Spare parts 15 1 15 3 After sales service 15 3 ...

Page 6: ...Contents EB 8052 E EN ...

Page 7: ...d fields of application as well as possible uses Reasonably foreseeable misuse The control valve is not suitable for the following applications Use outside the limits defined during sizing and by the technical data Use outside the limits defined 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 P...

Page 8: ...e fail safe position of the control valve upon air supply or control signal failure depends on the actuator used see associated actuator documentation When the valve is combined with a SAMSON Type 3271 or Type 3277 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 th...

Page 9: ...ponsibilities of operating personnel Operating personnel must read and understand these mounting and operating instructions as well as the referenced documents and observe the specified hazard statements warnings and caution notes Furthermore operating personnel must be familiar with the applicable health safety and accident prevention regulations and comply with them Referenced standards directiv...

Page 10: ...d operating instructions for the mounted actuator e g u EB 8310 X for the SAMSON Type 3271 or Type 3277 Pneumatic Actuator Mounting and operating instructions for mounted valve accessories positioner solenoid valve etc u AB 0100 for tools tightening torques and lubricant Manual u H 02 Appropriate Machinery Components for SAMSON Pneumatic Control Valves with a Declaration of Conformity of Final Mac...

Page 11: ...ntrol 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 Î Use suitable silencers and vent plugs Î Wear eye protection when working in close proximity to the control valve Crush hazard arising from moving parts The control valve contains moving parts actuator and plug or piston stem which can injure hands or fingers if ...

Page 12: ...t of the valve and depending on its properties cause personal injury e g chemical burns Î If possible drain the process medium from all the plant sections affected and the valve Î Wear protective clothing safety gloves respiratory protection and eye protection Risk of personal injury through incorrect operation use or installation as a result of information on the valve being illegible Over time m...

Page 13: ...components Excessive tightening torques lead to parts wearing out more quickly Parts that are too loose may cause leakage Î Observe the specified 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 Î Only use tools approved by SAMSON u AB 0100 Risk of valve damage due to the use of unsuitable lubricants The lubricants...

Page 14: ...o the yoke while the air supply is connected to the actuator 1 4 Notes on the use of an RFID tag The RFID tag is subject to certain restrictions due to its application range technical specifica tions Î Observe the explosion protection certificates of the RFID tag when it is to be used on valves installed in potentially explosive atmospheres Î Do not expose the RFID tag to strong electric fields Î ...

Page 15: ...HA carbide metal ST metal base material with Stellite facing KE ceramic PT PTFE soft seal PK PEEK soft seal 13 Seat code trim material on request 14 Pressure balancing DIN D ANSI JIS B Version M mixing valve V flow diverting valve Item Inscription meaning 15 Noise reduction 1 flow divider ST 1 2 ST 2 3 ST 3 1 PSA ST 1 standard and integrated in seat for PSA valve AC 1 AC 2 AC 3 AC 5 AC trim versio...

Page 16: ...im material This seat code is specified on the nameplate 2 4 Label when an adjustable packing is installed An instructional label is affixed to the valve when an adjustable packing is installed see Fig 2 3 Fig 2 3 Label when an adjustable packing is installed 2 5 Optional RFID tag The RFID tag is located directly next to the nameplate on valves ordered with the RFID tag option It contains the same...

Page 17: ...n the direction indicated by the arrow A rise in signal pressure causes the force acting on the diaphragm in the actuator to increase The springs are compressed Depending on the selected direction of action the actuator stem retracts or extends As a result the po sition of the plug 5 in the seat 4 or the po sition of the piston 5 in the cage 124 changes and determines the flow rate through the val...

Page 18: ...ellated nut 124 Seat retainer 126 Spiral gasket 127 Spiral gasket 162 Packing gland 163 Spring loading assembly packing 164 Stud for packing gland A4 Actuator diaphragm A7 Actuator stem A8 Ring nut A10 Actuator springs A26 A27 Stem connector clamps S Signal pressure connection 4 1 127 5 7 124 126 17 2 14 13 15 92 8 5 1 60 10 9 164 163 162 S A26 A27 A7 A8 A4 A10 Fig 3 1 Type 3251 E Valve with clamp...

Page 19: ... Yoke 92 Castellated nut 127 Spiral gasket 162 Packing gland 163 Spring loading assembly packing 164 Stud for packing gland 221 Seat ring A4 Actuator diaphragm A7 Actuator stem A8 Ring nut A10 Actuator springs A26 A27 Stem connector clamps S Signal pressure connection 4 1 127 221 5 7 17 2 5 1 14 13 15 92 8 60 10 9 164 163 162 S A26 A27 A7 A8 A4 A10 Fig 3 2 Type 3251 E Valve with screwed in seat an...

Page 20: ... 92 Castellated nut 124 Cage 126 Spiral gasket 127 Spiral gasket 162 Packing gland 163 Spring loading assembly packing 164 Stud for packing gland A4 Actuator diaphragm A7 Actuator stem A8 Ring nut A10 Actuator springs A26 A27 Stem connector clamps S Signal pressure connection 4 1 127 5 124 126 17 2 14 13 15 92 8 5 1 60 10 9 164 163 162 S A26 A27 A7 A8 A4 A10 45 63 Fig 3 3 Type 3251 E Valve with ca...

Page 21: ... valve the spring assembly in the actuator must be preloaded so that the travel ranges match See associ ated actuator documentation The basic pneumatic actuator can be re placed by a pneumatic actuator with addi tional handwheel or by an electric actuator see Information Sheet u T 8300 3 3 Accessories Transport eyelet swivel hoist Sprues fitted with a female thread on the valve body allow the atta...

Page 22: ...e decision is based on the risk posed by the plant and its operating condi tions Noise reduction Trims with flow divider ST 1 can be used to reduce noise emission u T 8081 3 5 Valve accessories Information Sheet u T 8350 3 6 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 More information is available...

Page 23: ...rmity 3 Temperature ranges 2 in F C Permissible operating pressures acc to pressure temperature dia grams see Information Sheet u T 8000 2 Body without insulating section Standard PTFE packing 14 to 428 10 to 220 LLF 20 PTFE packing 14 to 482 10 to 250 High temperature packing 14 to 662 10 to 350 Trim 1 Metal seal 325 to 1022 196 to 550 Balanced with PTFE 58 to 482 50 to 250 RFID tag optional Max ...

Page 24: ...g Plug 3 410 2 2 420 1 316 316L 2 316 316L 2 Seat 410 2 2 420 1 316 316L 2 316 316L 2 Fastening of the seat 410 2 316 316L Version with clamped in seat and plug Plug 3 410 2 2 420 1 316 316L 2 316 316L 2 Seat 410 2 2 420 1 316 316L 2 316 316L 2 Fastening of the seat A 217 WC 9 A351 CF8M Version with piston and cage Piston 410 2 1 420 1 316 316L 4 5 316 316L 4 5 Cage 410 2 1 420 1 316 316L 316 316L...

Page 25: ...1 613 H2 in 4 06 5 35 7 28 8 66 mm 103 136 185 220 H4 in 8 31 11 1 14 39 17 2 mm 211 283 365 5 437 H8 for actuator 175 to 350 cm in 9 45 mm 240 355 to 750 cm in 9 45 18 9 16 5 mm 240 480 418 1000 to 1400 60 cm in 11 6 16 5 mm 295 418 1400 120 to 2x 2800 120 cm Travel FA 30 75 FE 30 38 in 18 9 19 8 mm 480 503 Travel FE 30 38 in 21 1 mm 535 Travel FA 90 120 FE 60 120 in 25 6 mm 651 H5 in 4 13 0 02 5...

Page 26: ... 75 FE 30 38 in 7 09 7 68 mm 180 195 Travel FA 90 120 FE 60 120 in 9 45 mm 240 G for actuator 175 to 350 cm FA FE in 3 0 2 6 mm 75 67 355 to 750 cm FA FE in 3 5 3 5 3 5 3 7 mm 90 90 90 93 1000 to 1400 60 cm FA FE in 6 50 5 04 6 50 6 50 6 50 5 91 mm 165 128 165 165 165 150 1400 120 cm FA FE in 11 2 9 17 11 2 11 2 11 2 12 4 mm 285 233 285 285 285 315 2x 2800 120 cm FA FE in 12 4 9 17 12 4 11 2 12 4 ...

Page 27: ...50 cm lbs 141 150 154 255 271 357 549 578 586 836 888 952 kg 64 68 70 115 5 123 162 249 262 266 379 403 432 1000 to 1400 60 cm lbs 157 163 168 269 284 370 549 578 586 836 888 952 kg 71 74 76 122 129 168 249 262 266 379 403 432 1400 120 to 2x 2800 120 cm lbs 212 218 223 324 340 425 597 626 635 884 937 1001 kg 96 99 101 147 154 193 271 284 288 401 425 454 1 A With screwed in seat and plug B With cla...

Page 28: ... E 1 NPS 6 and larger with foot Type 3251 E 7 Up to NPS 4 without foot Type 3251 E 7 NPS 6 and larger with foot Refer to the following data sheet for more dimensions and weights u T 8052 E The associated actuator documentation applies to actuators e g for SAMSON pneumatic actuators u T 8310 1 for Type 3271 or Type 3277 Pneumatic Actuators up to 750 cm actuator area u T 8310 2 for Type 3271 Actuato...

Page 29: ...ection 4 2 Removing the packaging from the valve Observe the following sequence Î Do not open or remove the packaging until immediately before lifting to install the valve into the pipeline Î Leave the control valve in its transport container or on the pallet to transport it on site Î Do not remove the protective caps from the inlet and outlet until immediately before installing the valve into the...

Page 30: ...tation In contrast to the lifting eyelet eyebolt the swivel hoist is designed for setting a control valve assembly upright The sling between the swivel hoist and rig ging equipment hook shackle etc must not bear any load when lifting a control valve assembly The sling only protects the control valve from tilting while being lifted Our after sales service can provide more detailed transport and lif...

Page 31: ...ok shackle etc does not bear any load when lifting valves with an actuator that has a lifting eyelet eyebolt on it The sling only pro tects the control valve from tilting while being lifted Before lifting the control valve tighten the sling Lifting the control valve using a crossbeam See Fig 4 1 1 Screw tight the transport eyelets or swivel hoists into all four sprues on the valve body see Accesso...

Page 32: ...ods Storage instructions Protect the control valve against external influences e g impact Do not damage the corrosion protection paint surface coatings Repair any damage immediately Protect the control valve 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 ...

Page 33: ...lastomer e g actuator diaphragm To keep elastomers in shape and to pre vent cracking do not bend them or hang them up We recommend a storage temperature of 15 C 59 F for elastomers Store elastomers away from lubricants chemicals solutions and fuels SAMSON s After sales Service can provide more detailed storage instructions on re quest Tip ...

Page 34: ...4 6 EB 8052 E EN ...

Page 35: ...t and outlet lengths see Table 5 1 vary depending on several variables and process conditions and are intended as recommendations Contact SAMSON if the lengths are significantly shorter than the recommended lengths Table 5 1 Inlet and outlet lengths Q a x NPS b x NPS State of process medium Valve conditions Inlet length a Outlet length b Gas Ma 0 3 2 4 0 3 Ma 0 7 2 10 Vapor Ma 0 3 1 2 4 0 3 Ma 0 7...

Page 36: ...lves which are not installed in the pipeline in the upright position with the actuator on top must be supported or suspended The plant engineering company is responsi ble for selecting and implementing a suitable support or suspension of the installed control valve and the pipeline Valve accessories Î During connection of valve accessories make sure that they are easily accessible and can be opera...

Page 37: ...the pipelines in the plant Î For steam applications dry the pipelines Moisture will damage the inside of the valve Î Check any mounted pressure gauges to make sure they function properly Î When the valve and actuator are al ready assembled check the tightening torques of the bolted joints u AB 0100 Components may loosen during trans port 5 3 Mounting the device The activities listed below are nece...

Page 38: ...85 ac cording to Table 5 4 6 Use a soft faced hammer or lever press to press the sliding washers 309 with their beveled part first without using any lubricant into the recesses of the clamps 301 as far as they will go Remove any excess material 7 Apply a thin film of lubricant 114 to the threads of the stem 9 and screws 303 Impaired functioning due to incorrectly applied lubricant Î Do not apply a...

Page 39: ... Warning label 310 Ball bearing Plug or piston stem Fig 5 1 Overview of yoke assembly with travel indicator scale in the standard version on each side see detailed view Y in Fig 5 2 The anti rotation fixture does not get stuck on the yoke and can move free ly in the direction of travel 14 Extend the actuator stem again and mount the stem connector clamps ...

Page 40: ...01 309 309 9 303 304 114 Y 1 0 0 5 Y 1 0 0 5 Legend 9 Stem 114 Lubricant Gleitmo 1763 V 301 Clamps 303 Screws 304 Washers 309 Sliding washers Plug or piston stem Fig 5 2 Overview of anti rotation fixture assembly in the standard version ...

Page 41: ...correctly ap plied lubricant Î Do not apply any lubricant to the threads of the clamps 301 or plug piston stem 6 Position the clamps 301 and stem 9 on the plug or piston stem according to Table 5 4 and tighten screws 303 and washers 304 by hand 7 Mount the actuator See section 5 3 2 8 Thread the stem 9 upwards until the head of the stem rests on the extended actuator stem 9 Retract the actuator st...

Page 42: ...Screws 83 Hanger 84 Travel indicator scale 92 Castellated nut 255 Warning label 302 Holder 306 Screws 308 Washers 83 82 84 92 3 306 308 302 255 Plug or piston stem Fig 5 3 Overview of yoke assembly with travel indicator scale in the special version ...

Page 43: ...301 309 309 304 303 9 114 Y Y 1 0 0 5 1 0 0 5 Legend 9 Stem 114 Lubricant Gleitmo 1763 V 301 Clamps 303 Screws 304 Washers 309 Sliding washers Plug or piston stem Fig 5 4 Overview of anti rotation fixture assembly in the special version ...

Page 44: ...5 7 5 103 5 82 5 34 5 30 1000 1400 60 15 100 60 136 105 30 75 45 121 120 1400 120 30 75 90 231 195 2800 30 100 120 231 195 NPS 6 Standard version 355 700 750 15 0 0 263 5 67 5 192 87 48 105 70 145 15 50 15 256 75 145 15 75 22 5 263 5 67 5 145 30 0 0 241 90 120 30 25 7 5 248 5 82 5 120 1000 1400 60 15 100 60 226 105 103 30 0 0 211 120 88 30 75 45 211 120 88 60 0 0 166 165 58 60 25 15 181 150 58 140...

Page 45: ...ion 355 700 750 30 0 0 241 90 195 87 61 108 65 120 1000 1400 60 30 0 0 211 120 66 83 30 75 45 211 120 66 83 60 0 0 166 165 52 55 60 25 15 181 150 52 55 1400 120 15 87 5 105 236 180 61 115 30 0 0 191 225 48 76 30 75 90 221 195 61 100 60 0 0 308 255 61 185 60 50 60 191 225 48 76 2800 5600 30 0 0 191 225 48 76 30 100 120 221 195 61 100 60 0 0 308 255 61 185 60 75 90 191 225 48 76 ...

Page 46: ...5 12 EB 8052 E EN Installation H G H F H N H O H L H T H K H I Ball bearings standard version only Fig 5 5 Dimensional drawing with mounting dimensions for Types 3271 and 3277 Pneumatic Actuators ...

Page 47: ...ator stem and the stem 9 Î First remove the actuator from the valve or ensure it cannot transmit any forces to the actuator stem before removing the anti rotation fixture on the plug stem Depending on the version SAMSON control valves are either delivered with the actuator already mounted on the valve or the valve and actuator are delivered separately When delivered separately the valve and actuat...

Page 48: ...ine Premature wear and leakage due to insufficient support or suspension Î Support or suspend the valve sufficiently at suitable points 1 Close the shut off valves in the pipeline at the inlet and outlet of the plant section while the valve is being installed 2 Prepare the relevant section of the pipe line for installing the valve 3 Remove the protective caps from the valve ports before installing...

Page 49: ...fitted with noise reducing fittings Both can damage hearing Î Wear hearing protection when working near the valve Crush hazard arising from moving parts actuator and plug or piston stem Î Do not insert hands or finger into the yoke while the air supply is connected to the actuator Î Before working on the control valve dis connect and lock the pneumatic air sup ply as well as the control signal Î D...

Page 50: ...the valve A sudden surge in pressure and resulting high flow velocities can damage the valve 3 Open the valve 4 Apply the required test pressure 5 Check the valve for leakage to the atmo sphere 6 Depressurize the pipeline section and valve 7 Rework any parts that leak see informa tion below under Adjusting the packing and repeat the leak test Adjusting the packing A label on the yoke indicates whe...

Page 51: ...e groove at the bottom of the guide bolts 163 1 is flush with the bottom of the packing gland 162 See Fig 5 8 2 Open and close the valve several times 3 Check the valve for leakage to the atmo sphere Î If the adjustable packing does not seal properly contact our after sales service Î If tightening of the adjustable packing is no longer possible because it has its elasticity see Fig 5 11 it must be...

Page 52: ... positions of the valve while observing the movement of the actuator stem Î Check the travel reading at the travel in dicator scale 5 4 3 Fail safe position Î Shut off the signal pressure line Î Check whether the valve moves to the fail safe position see the Design and principle of operation section 5 4 4 Pressure test The plant operator is responsible for per forming the pressure test Our after s...

Page 53: ...ing parts actuator and plug or piston stem Î Do not insert hands or finger into the yoke while the air supply is connected to the actuator Î Before working on the control valve disconnect and lock the pneumatic air supply as well as the control signal Î Do not impede the movement of the actuator and plug or piston stem by inserting objects into the yoke Î Before unblocking the actuator and plug or...

Page 54: ...ions and measures section Start up putting the valve back into opera tion 1 Allow the valve to cool down or warm up to reach ambient temperature before start up when the ambient temperature and process medium temperature differ greatly or the medium properties require such a measure 2 Slowly open the shut off valves in the pipeline Slowly opening these valves prevents a sudden surge in pressure an...

Page 55: ...ing protection when working near the valve Crush hazard arising from moving parts actuator and plug or piston stem Î Do not insert hands or finger into the yoke while the air supply is connected to the actuator Î Before working on the control valve disconnect and lock the pneumatic air supply as well as the control signal Î Do not impede the movement of the actuator and plug or piston stem by inse...

Page 56: ...The handwheel of valves with actuators fitted with a handwheel must be in the neutral po sition during normal operation 7 2 Manual operation Valves with actuators fitted with a handwheel can be manually closed or opened in case of supply air failure ...

Page 57: ...r documentation Diaphragm in the actuator defective See associated actuator documentation Signal pressure too low Check the signal pressure Check the signal pressure line for leakage Jolting movement of the actuator and plug or piston stem Version with adjustable packing 1 packing not tightened correctly Tighten the packing correctly see information under Adjusting the packing in the Installa tion...

Page 58: ... See the Start up section Malfunction Possible reasons Recommended action The valve leaks to the atmosphere fugitive emissions Defective packing Replace packing see the Servicing section or contact our after sales service Version with adjustable packing 1 packing not tightened correctly Adjust the packing see information under Adjusting the packing in the Installation section Testing the installed...

Page 59: ...e components and the pipeline may be come very hot or cold Risk of burn injuries Î Allow components and pipelines to cool down or warm up to the ambient tem perature Î Wear protective clothing and safety gloves Risk of hearing loss or deafness due to loud noise Noise emission e g cavitation or flashing may occur during operation caused by the process medium and the operating conditions Additionall...

Page 60: ...ium can flow out of the valve and depend ing on its properties cause personal injury e g chemical burns Î Wear protective clothing safety gloves respiratory protection and eye protec tion Risk of valve damage due to excessively high or low tightening torques Observe the specified torques when tighten ing control valve components Excessive tightening torques lead to parts wearing out more quickly P...

Page 61: ...inspection and test plan Our after sales service can support you in drawing up an inspection and test plan for your plant Note Tip We recommend the following inspection and testing which can be performed while the pro cess is running Inspection and testing Action to be taken in the event of a negative result Check the markings labels and name plates on the valve for their readability and completen...

Page 62: ...ormation under Adjusting the packing in the Installation section Testing the installed valve Unblock a blocked actuator and plug or piston stem WARNING A blocked actuator or plug or piston stem e g due to seizing up after remaining in the same position for a long time can suddenly start to move uncontrollably Injury to hands or fingers is possible if they are inserted into the actuator or valve Be...

Page 63: ...ssure balancing Î Contact our after sales service for service or conversion work on valve versions with pressure balancing 1 Lay out the necessary material and tools to have them ready for the intended work 2 Put the control valve out of operation see the Decommissioning section 3 Remove the actuator from the valve See associated actuator documentation To remove an actuator with stem extends fail ...

Page 64: ...d the Installation sec tion 2 Adjust lower or upper signal bench range See associated actuator docu mentation 3 If the valve has been removed re install the valve into the pipeline see the Instal lation section 4 Put the control valve back into operation see the Start up section Observe the requirements and conditions for start up or putting the valve back into operation ...

Page 65: ...ted nut 124 Seat retainer 126 Spiral gasket 127 Spiral gasket 162 Packing gland 163 Spring loading assembly packing 164 Stud for packing gland A4 Actuator diaphragm A7 Actuator stem A8 Ring nut A10 Actuator springs A26 A27 Stem connector clamps S Signal pressure connection 4 1 127 5 7 124 126 17 2 14 13 15 92 8 5 1 60 10 9 164 163 162 S A26 A27 A7 A8 A4 A10 Fig 9 1 Type 3251 E Valve with clamped i...

Page 66: ...e 92 Castellated nut 127 Spiral gasket 162 Packing gland 163 Spring loading assembly packing 164 Stud for packing gland 221 Seat ring A4 Actuator diaphragm A7 Actuator stem A8 Ring nut A10 Actuator springs A26 A27 Stem connector clamps S Signal pressure connection 4 1 127 221 5 7 17 2 5 1 14 13 15 92 8 60 10 9 164 163 162 S A26 A27 A7 A8 A4 A10 Fig 9 2 Type 3251 E Valve with screwed in seat and Ty...

Page 67: ...astellated nut 124 Cage 126 Spiral gasket 127 Spiral gasket 162 Packing gland 163 Spring loading assembly packing 164 Stud for packing gland A4 Actuator diaphragm A7 Actuator stem A8 Ring nut A10 Actuator springs A26 A27 Stem connector clamps S Signal pressure connection 4 1 127 5 124 126 17 2 14 13 15 92 8 5 1 60 10 9 164 163 162 S A26 A27 A7 A8 A4 A10 45 63 Fig 9 3 Type 3251 E Valve with cage tr...

Page 68: ...ot undo the clamps 301 until the valve bonnet assembly has been separat ed from the plug or piston stem 5 1 9 4 1 Replacing the gaskets Risk of valve malfunction due to damaged parts Î Clean and check all the seating surfaces in the body and all other parts that come into contact with the gaskets to ensure they are free from damage before install ing any new gaskets Î Renew any parts with damaged ...

Page 69: ...e that the largest V shaped port of the V port plug faces toward the valve outlet See information under Mounting the ac tuator onto the valve in the Installation section 15 Press plug 5 firmly into the seat 4 while fastening down the valve bonnet 2 with the body nuts 14 Tighten the body nuts 14 gradually in a crisscross pattern Observe tightening torques b Version with screwed in seat and plug Ris...

Page 70: ...1 in the seat bridge area 11 NPS 3 and 4 only place seat 4 onto the spiral gasket 127 in the body 1 12 NPS 3 and 4 only apply a suitable lu bricant 114 to the thread and seating surface of the seat ring 221 Screw the seat ring 221 by hand a few turns into the body 1 13 NPS 3 and 4 only tighten the seat ring 221 using a special tool u AB 0100 Observe tightening torques 14 Valve versions without flo...

Page 71: ...ard packing apply a suitable lu bricant 113 to all the packing parts and to the plug or piston stem 5 1 HT packing do not use any lubricant 12 Insert the plug piston 5 together with the plug piston stem 5 1 vertically into the valve body 1 and position it in the seat 4 in the closed position Version with V port plug align the plug 5 making sure that the largest V shaped port of the V port plug fac...

Page 72: ...9 6 Continue as described in steps 6 to 18 of the previously described procedure Valve versions without anti rotation fix ture under a on page 9 13 7 Apply a thin film of lubricant 114 to the screws 303 Impaired functioning due to incorrectly applied lubricant Î Do not apply any lubricant to the threads of the clamps 301 stem 9 or plug piston stem 8 Position the clamps 301 and stem 9 on the plug o...

Page 73: ...the stem connector nut 9 and lock nut 10 from the plug or piston stem 5 1 5 Gradually unscrew the two guide bolts 163 1 of the spring loading assemblies 163 at the hex head in a crisscross pat tern 6 Lift off the two spring loading assemblies 163 and packing gland 162 vertically over the studs 164 off the valve bonnet 2 7 Unscrew castellated nut 92 and lift the yoke 60 off the valve bonnet 2 8 Pul...

Page 74: ...0 Place packing gland 162 over the studs 164 on the valve body 2 onto the packing follower 8 21 Screw the two spring loading assemblies 163 onto the studs 164 and guide them through the holes on the packing gland 22 Adjust the packing see information un der Adjusting the packing in the Instal lation section Testing the installed valve Leak test 23 Loosely thread lock nut 10 and stem connector nut ...

Page 75: ...g dimensions table in the Installation section under Mounting the external anti rotation fixture and tighten screws 303 and washers 304 by hand 15 4 15 2 15 10 15 5 The bushings 15 5 may deviate from those illustrated Legend 15 2 Packing 15 4 Anti extrusion rings 15 5 Bushing 15 10 Washer Fig 9 6 Arrangement of LLF 20 packing Note ...

Page 76: ... anti rotation fixture undo the screws 303 and remove the clamps 301 of the anti rotation fixture Set aside clamps 301 screws 303 washers 304 and stem 9 6 Unscrew castellated nut 92 and lift the yoke 60 off the valve bonnet 2 7 Unscrew the threaded bushing 8 8 Pull plug stem 5 1 out of the valve bon net 2 9 Pull the entire packing out of the packing chamber using a suitable tool 10 Clean the packi...

Page 77: ...m the body 1 For versions NPS 6 a special SAMSON tool is available u AB 0100 14 Remove seat 4 and spiral gasket 127 from the body 1 b Removing the screwed in seat and plug Risk of control valve damage due to incor rect servicing or conversion Î Do not attempt to remove the seat and plug yourself in the valve version NPS 6 and 8 with screwed in seat and plug Î Contact our after sales service Standa...

Page 78: ...ions with anti rotation fixture ensure that the clamps 301 are still fas tened tight to the plug stem 5 1 3 Lift the valve bonnet 2 including yoke 60 plug 5 and plug stem 5 1 up wards off the body 1 and set it aside 4 Valve versions without anti rotation fix ture unscrew the stem connector nut 9 and lock nut 10 from the plug stem 5 1 Valve versions with anti rotation fixture undo the screws 303 an...

Page 79: ...5 1 Valve versions with anti rotation fixture undo the screws 303 and remove the clamps 301 of the anti rotation fixture Set aside clamps 301 screws 303 washers 304 and stem 9 6 Unscrew castellated nut 92 and lift the yoke 60 off the valve bonnet 2 7 Unscrew the threaded bushing 8 8 Pull piston stem 5 1 out of the valve bonnet 2 9 Pull the entire packing out of the packing chamber using a suitable...

Page 80: ...ng equip ment is available from SAMSON u AB 0100 14 Remove seat 4 and spiral gasket 127 from the body 1 d Installing the clamped in seat and plug 1 Clean the inside of the valve body seat ing surfaces of the gaskets and check it to ensure that it is free from damage 2 Insert a new spiral gasket 127 into the body 1 in the seat bridge area 3 Place seat 4 onto the spiral gasket 127 in the body 1 4 Gu...

Page 81: ...r Adjusting the packing in the Instal lation section Testing the installed valve Leak test 16 Loosely screw lock nut 10 and stem connector nut 9 onto the plug stem 5 1 Valve version with anti rotation fixture 7 Continue as described in steps 7 to 15 of the previously described procedure Valve version without anti rotation fix ture on page 9 22 8 Apply a thin film of lubricant 114 to the threads of...

Page 82: ...n Version with V port plug align the plug 5 making sure that the largest V shaped port of the V port plug faces toward the valve outlet See information under Mounting the actuator onto the valve in the Installation section 10 Loosely place the valve bonnet 2 over the plug stem 5 1 onto the body 1 11 Press plug 5 firmly into the seat 4 while fastening down the valve bonnet 2 with the body nuts 14 T...

Page 83: ...4 Guide cage 124 into the body 1 and position it onto the seat 4 5 Insert piston 5 together with the piston stem 5 1 through the cage 124 verti cally into the valve body 1 and position it on the seat 4 6 Apply a suitable lubricant 113 to the piston stem 5 1 7 Insert a new gasket 45 onto the cylin der 63 Make sure the gasket is proper ly aligned see Fig 9 7 8 Place cylinder 63 together with the gas...

Page 84: ...nstalled valve Leak test 19 Loosely thread lock nut 10 and stem connector nut 9 onto the piston stem 5 1 Valve version with anti rotation fixture 11 Continue as described in steps 11 to 18 of the previously described procedure Valve version without anti rotation fix ture on page 9 25 12 Apply a thin film of lubricant 114 to the threads of the stem 9 and screws 303 Impaired functioning due to incor...

Page 85: ... spare parts and operating supplies Contact your nearest SAMSON subsidiary or SAMSON s After sales Service for infor mation on spare parts lubricants and tools Spare parts See Annex for details on spare parts Lubricant See document u AB 0100 for details on suitable lubricants Tools See document u AB 0100 for details on suitable tools ...

Page 86: ...9 28 EB 8052 E EN Servicing and conversion ...

Page 87: ...thing and safety gloves Risk of hearing loss or deafness due to loud noise Noise emission e g cavitation or flashing may occur during operation caused by the process medium and the operating conditions Additionally a loud noise may briefly occur through the sudden venting of the pneumatic actuator or pneumatic valve accessories not fitted with noise reducing fittings Both can damage hearing Î Wear...

Page 88: ...ts properties cause personal injury e g chemical burns Î Wear protective clothing safety gloves respiratory protection and eye protec tion To decommission the control valve for service work or to remove it from the pipeline pro ceed as follows 1 Close the shut off valves upstream and downstream of the control valve to stop the process medium from flowing through the valve 2 Completely drain the pi...

Page 89: ...long time release any stored energy in the actuator e g spring compression See associated actuator documentation Risk of personal injury due to residual process medium in the valve While working on the valve residual me dium can flow out of the valve and depend ing on its properties cause personal injury e g chemical burns Î Wear protective clothing safety gloves respiratory protection and eye pro...

Page 90: ... valve make sure the fol lowing conditions are met The control valve is put out of operation see the Decommissioning section 11 1 Removing the valve from the pipeline 1 Support the valve to hold it in place when separated from the pipeline see the Shipment and on site transport sec tion 2 Unbolt the flange joint 3 Remove the valve from the pipeline see the Shipment and on site transport sec tion 1...

Page 91: ...e Support After sales Service 2 Send an e mail u retouren samsongroup com to register the return shipment including the following information Type Article no Configuration ID Original order Completed Declaration on Contamination which can be downloaded from our website at u www samsongroup com Service Support After sales Service After checking your registration we will send you a return merchandis...

Page 92: ...12 2 EB 8052 E EN ...

Page 93: ...B 8052 E EN 13 1 Disposal 13 Disposal Î Observe local national and internation al refuse regulations Î Do not dispose of components lubricants and hazardous substances together with your household waste ...

Page 94: ...13 2 EB 8052 E EN ...

Page 95: ...y in compliance with Pressure Equipment Directive 2014 68 EU on page 14 2 The certificates shown were up to date at the time of publishing The latest certificates can be found on our website u www samsongroup com Products Applications Product selector Valves 3251 E Other optional certificates are available on request ...

Page 96: ...14 2 EB 8052 E EN ...

Page 97: ...sket 47 Support element 48 Hex screw 49 Hex screw 50 Tamper proof seal 51 Guide ring 52 Ring version with graphite gasket only 53 Snap ring 60 Yoke assembly 62 Flow divider ST 1 1 63 Cylinder version with pressure balancing clamping element 1 version with flow divider 91 Protective caps for flanges 92 Castellated nut 113 Lubricant 114 Lubricant 124 Seat retainer cage 126 Spiral gasket 127 Spiral g...

Page 98: ...15 2 EB 8052 E EN 163 10 60 9 92 7 5 124 126 4 127 91 1 13 221 5 5 63 126 124 4 45 127 2 14 15 17 8 162 164 8 50 47 44 46 52 45 48 53 51 48 51 53 52 45 50 44 47 46 49 ...

Page 99: ... The addresses of SAMSON AG its subsid iaries representatives and service facilities worldwide can be found on our website www samsongroup com or in all SAMSON product catalogs Required specifications Please submit the following details Order number and position number in the order Type model number valve size and valve version Pressure and temperature of the process medium Flow rate in m h Direct...

Page 100: ...15 4 EB 8052 E EN ...

Page 101: ......

Page 102: ...2021 06 09 English SAMSON AKTIENGESELLSCHAFT Weismüllerstraße 3 60314 Frankfurt am Main Germany Phone 49 69 4009 0 Fax 49 69 4009 1507 samson samsongroup com www samsongroup com EB 8052 E EN ...

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