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Samson 3256, Mounting And Operating Instructions, Page: 84 / 84

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Samson 3256 Mounting And Operating Instructions Download Page 84

2020-06-08 · Engl

ish

SAMSON AKTIENGESELLSCHAFT
Weismüllerstraße 3 · 60314 Frankfurt am Main, Germany
Phone: +49 69 4009-0 · Fax: +49 69 4009-1507
[email protected] · www.samsongroup.com

EB 8065 EN

Summary of Contents for 3256

Page 1: ...ation of original instructions EB 8065 EN Edition May 2020 Type 3256 Valve DIN version In combination with an actuator e g a Type 3271 or Type 3277 Pneumatic Actuator Type 3256 Valve with Type 3271 Ac...

Page 2: ...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 instructi...

Page 3: ...Accessories 3 4 3 5 Technical data 3 4 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...

Page 4: ...ice work 9 5 9 4 1 Replacing the gasket 9 5 9 4 2 Replacing the packing 9 6 9 4 3 Replacing the seat and plug 9 12 9 5 Ordering spare parts and operating supplies 9 14 10 Decommissioning 10 1 11 Remov...

Page 5: ...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...

Page 6: ...ith 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 f...

Page 7: ...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 a...

Page 8: ...ible severe personal injury DANGER Risk of bursting in pressure equipment Valves and pipelines are pressure equipment Impermissible pressure or improper opening can lead to valve components bursting O...

Page 9: ...jure hands or fingers if inserted into the valve Do not insert hands or finger into the yoke while the air supply is connected to the actuator Before working on the control valve disconnect and lock t...

Page 10: ...labels and nameplates on the valve may become covered with dirt or become illegible in some other way As a result hazards may go unnoticed and the necessary instructions not followed There is a risk...

Page 11: ...o the use of unsuitable tools Certain tools are required to work on the valve Only use tools approved by SAMSON u AB 0100 Risk of valve damage due to the use of unsuitable lubricants The lubricants to...

Page 12: ...Warning Meaning of the warning Location on the device Warning against moving parts There is a risk of injury to hands or fingers through the stroking movement of the actuator and plug stem if they are...

Page 13: ...eal ME metal 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 Ve...

Page 14: ...of the valves have an item number written on them You can contact us stating this item number to find out which material is used Additionally a seat code is used to identify the trim material This sea...

Page 15: ...plug position in the seat changes and determines the flow rate through the valve The direction of flow is different for the ver sion with a ceramic anti wear sleeve the medium flows through the valve...

Page 16: ...h plug stem 8 Threaded bushing packing nut 9 Stem connector nut 10 Lock nut 14 Body nut 15 Packing 17 Body gasket 84 Travel indicator scale 92 Castellated nut A4 Diaphragm A7 Actuator stem A8 Ring nut...

Page 17: ...the actuator is larger than the travel range of the valve the spring assembly in the actuator must be preloaded so that the travel ranges match See associ ated actuator documentation The basic pneuma...

Page 18: ...iding whether a guard is to be used The decision is based on the risk posed by the plant and its operating conditions 3 4 Accessories Information Sheet u T 8350 3 5 Technical data The nameplates on th...

Page 19: ...ges in C Permissible operating pressures acc to pressure temperature diagram see Information Sheet u T 8000 2 Body without insulating section 10 to 220 C Up to 350 C with high temperature packing Body...

Page 20: ...75 325 PN 250 115 130 150 175 225 260 350 400 PN 320 115 130 150 175 225 260 350 400 PN 400 127 1 150 1 189 1 222 1 285 1 333 1 454 1 On re quest Height H4 PN 10 to 160 134 129 129 175 160 170 210 On...

Page 21: ...rawing H4 H8 L L Type 3256 Refer to the following data sheets for more dimensions and weights u T 8065 for valves with bellows seal insulating section or heating jacket The associated actuator documen...

Page 22: ...3 8 EB 8065 EN...

Page 23: ...a section 4 2 Removing the packaging from the valve Observe the following sequence Do not open or remove the packaging until immediately before lifting to install the valve into the pipeline Leave the...

Page 24: ...ngs to the actuator handwheel or any other parts Observe lifting instructions see sec tion 4 3 2 A swivel hoist can be screwed into SAMSON actuators with a female thread on the top diaphragm case in p...

Page 25: ...e axis of the plug stem is always vertical Note Make sure that the additional sling be tween the lifting eyelet and rigging equipment hook shackle etc does not bear any load when lifting valves larger...

Page 26: ...e humidity of less than 75 In damp spaces prevent condensation If necessary use a drying agent or heating Make sure that the ambient air is free of acids or other corrosive media The permissible stora...

Page 27: ...e of stress and with the least amount of vibrations as possible Read Mounting position and Support or suspension in this section Install the valve allowing sufficient space to remove the actuator and...

Page 28: ...rk position of operating person nel Table 5 1 Inlet and outlet lengths Q b x DN a x DN Q Flow rate a Inlet length b Outlet length State of process medium Valve conditions Inlet length a Outlet length...

Page 29: ...on properly Do not insulate valves mounted to com ply with NACE MR0175 requirements and which have nuts and bolts that are not suitable for sour gas environments Proceed as follows Lay out the necessa...

Page 30: ...Fasten the hanger 83 and warning la bel 255 if applicable to the yoke us ing the screws 82 5 Position the travel indicator scale 84 on the hanger 83 with the screws 85 ac cording to Table 5 4 6 Use a...

Page 31: ...e standard version Table 5 2 Tightening torques Screw size Tightening torque Nm M12 50 M16 121 13 Check and ensure the following points There is a nominal gap between 0 5 and 1 mm between the slider d...

Page 32: ...301 301 309 309 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 Slider disks Plug stem Fig 5 2 Overview of anti rotation fixture asse...

Page 33: ...lubricant Do not apply any lubricant to the stem 9 plug stem or the threads of the clamps 301 6 Position the clamps 301 and stem 9 on the plug stem according to Table 5 4 and tighten screws 303 and w...

Page 34: ...82 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 stem Fig 5 3 Overview of yoke assembly with trav...

Page 35: ...301 301 309 309 304 303 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 Slider disks Plug stem Fig 5 4 Overview of anti rotation fixture asse...

Page 36: ...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 DN 125 to 150 NPS 6 Standard version 355 700 750 15 0 0 263 5 67 5 192 87 48 10...

Page 37: ...0 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 DN 250 NPS 10 seat bore 250 an...

Page 38: ...5 12 EB 8065 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 39: ...he flow first when the valve opens facing toward the valve outlet This is the largest of the three V shaped ports see Fig 5 6 Before mounting the actuator determine which V shaped port is uncovered fi...

Page 40: ...nder Ver sion with flanges steps 1 to 4 2 Completely retract the actuator stem to protect the plug from sparks during weld ing Stem extends direction of action apply a signal pressure to the actuator...

Page 41: ...t of the actu ator and plug stem by inserting objects into the yoke Before unblocking the actuator and plug stem after they have become blocked e g due to seizing up after remaining in the same positi...

Page 42: ...ck 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 Adjus...

Page 43: ...fe position Shut off the signal pressure line 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 respon...

Page 44: ...5 18 EB 8065 EN...

Page 45: ...or pneumatic valve accessories not fitted with noise reducing fittings Both can damage hearing Wear hearing protection when working near the valve Crush hazard arising from actuator and plug stem movi...

Page 46: ...sizing requirements see information under In tended use in the Safety instructions and measures section Start up putting the valve back into opera tion 1 Allow the valve to cool down or warm up to rea...

Page 47: ...lve accessories not fitted with noise reducing fittings Both can damage hearing Wear hearing protection when working near the valve Crush hazard arising from actuator and plug stem moving Do not inser...

Page 48: ...e 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...

Page 49: ...entation 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...

Page 50: ...ssible 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 adjus...

Page 51: ...due to hot or cold components and pipeline Valve components and the pipeline may be come very hot or cold Risk of burn injuries Allow components and pipelines to cool down or heat up Wear protective...

Page 52: ...ator Before starting any work on the actuator relieve the compression from the pre loaded springs see associated actuator documentation Risk of personal injury due to residual pro cess medium in the...

Page 53: ...ng the packing in the Testing the installed valve section If the packing leaks continuously replace the packing see section 9 4 2 The control valve was checked by SAMSON before it left the factory Cer...

Page 54: ...they are mounted properly Tighten the connections of the valve accessories Check to ensure that the actuator and plug stem move smoothly Version with adjustable packing 1 tighten the packing cor rect...

Page 55: ...tion 9 4 1 Replacing the packing see section 9 4 2 Replacing the seat and plug see sec tion 9 4 3 9 3 Mounting the valve after service work 1 Mount actuator See associated actuator documentation 2 Adj...

Page 56: ...2 Lift the insulating section 21 or bellows seal 22 and plug with plug stem 5 off the body 1 3 Remove the gasket 17 Carefully clean the sealing faces in the valve body 1 and on the insulating section...

Page 57: ...m 8 Threaded bushing packing nut 9 Stem connector nut 10 Lock nut 14 Body nut 15 Packing 17 Body gasket 21 Insulating section 84 Travel indicator scale 92 Castellated nut A4 Diaphragm A7 Actuator stem...

Page 58: ...g with plug stem 5 out of the bonnet 2 7 Pull the entire packing out of the packing chamber using a suitable tool 8 Renew damaged parts Clean the pack ing chamber thoroughly 9 Apply a suitable lubrica...

Page 59: ...ng 15 1 between the threaded bushing 8 and retaining ring See Fig 9 4 5 Proceed as described in Standard pack ing PTFE steps 13 to 16 b Version with insulating section Standard packing PTFE 1 Unscrew...

Page 60: ...ly in a crisscross pattern Ob serve tightening torques 14 Screw in the threaded bushing 8 and tighten it Observe tightening torques 15 Place yoke 3 on the insulating section 21 and fasten tight using...

Page 61: ...ring 12 Washer 15 Packing entire 15 1 Spacer ring with retaining ring 15 2 Seal 16 Packing ring 18 Bushing 19 Spacer Fig 9 4 ADSEAL packing DN 15 to 40 left and DN 50 to 100 right 4 Insert the red spa...

Page 62: ...ed nut 92 and lift the yoke 3 off the bonnet 2 2 Undo the body nuts 14 gradually in a crisscross pattern 3 Lift the bonnet 2 and plug with plug stem 5 off the body 1 4 Replace the gasket as described...

Page 63: ...sscross pattern 3 Lift the insulating section 21 together with the plug stem and plug 5 off the body 1 4 Replace the gasket as described in sec tion 9 4 1 5 Unthread the stem connector nut 9 and lock...

Page 64: ...threaded bushing 8 and tighten it Observe tightening torques 19 Place yoke 3 on the insulating section 21 and fasten tight using the castellated nut 92 20 Loosely screw the lock nut 10 and stem connec...

Page 65: ...clothing and safety gloves Risk of personal injury due to pressurized components and process medium being discharged Do not loosen the screw of the test con nection while the valve is pressurized Ris...

Page 66: ...he valve While working on the valve residual medium can flow out of the valve and depending on its properties cause personal injury e g chemical burns Wear protective clothing safety gloves respirator...

Page 67: ...r and plug stem after they have become blocked e g due to seizing up after remaining in the same position for a long time release any stored energy in the actuator e g spring compression See associate...

Page 68: ...move the valve from the pipeline see the Shipment and on site transport sec tion b Version with welding ends 1 Support the valve to hold it in place when separated from the pipeline see the Shipment a...

Page 69: ...r sales Service 2 Send an e mail u retouren sam songroup com to register the return ship ment including the following information Type Article number Configuration ID Original order Completed Declarat...

Page 70: ...12 2 EB 8065 EN...

Page 71: ...EB 8065 EN 13 1 Disposal 13 Disposal Observe local national and internation al refuse regulations Do not dispose of components lubricants and hazardous substances together with your household waste...

Page 72: ...13 2 EB 8065 EN...

Page 73: ...re Equipment Directive 2014 68 EU on page 14 2 Declaration of conformity in compliance with Machinery Directive 2006 42 EC for Types 3256 1 and 3256 7 Control Valves on page 14 3 Declaration of incorp...

Page 74: ...14 2 EB 8065 EN...

Page 75: ...EB 8065 EN 14 3...

Page 76: ...14 4 EB 8065 EN...

Page 77: ...Ring ring nut 1 45 Packing ring 1 46 Gasket 1 47 Support 1 48 Hex screw 1 49 Hex screw 1 50 Lock 1 51 Guide 1 several guides only for version with graphite seal 52 Ring 1 only for version with graphit...

Page 78: ...80 81 92 83 32 84 85 82 42 16 19 94 37 39 7 101 33 14 93 39 22 2 81 26 7 24 5 14 93 26 81 8 16 12 19 12 11 15 5 102 48 51 47 53 44 52 45 50 46 49 50 46 52 44 47 96 48 53 51 62 61 6 29 27 28 29 34 31...

Page 79: ...iaries 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 specific...

Page 80: ...15 4 EB 8065 EN...

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Page 84: ...2020 06 08 English SAMSON AKTIENGESELLSCHAFT Weism llerstra e 3 60314 Frankfurt am Main Germany Phone 49 69 4009 0 Fax 49 69 4009 1507 samson samsongroup com www samsongroup com EB 8065 EN...

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