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Samson 3595, Mounting And Operating Instructions, Page: 2 / 76

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Samson 3595 Mounting And Operating Instructions Download Page 2

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. The images shown in 
these instructions are for illustration purposes only. The actual product may vary.

 

Î

For the safe and proper use of these instructions, read them carefully and keep them for 
later reference.

 

Î

If you have any questions about these instructions, contact SAMSON‘s After-sales Service 

Department (

[email protected]).

The mounting and operating instructions for the devices are included in 
the scope of delivery. The latest documentation is available on our web-

site at 

www.samsongroup.com > Service & Support > Downloads > Doc-

umentation

.

 Definition 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

 

EB 8079 EN

Summary of Contents for 3595

Page 1: ...n of original instructions EB 8079 EN Edition November 2019 Type 3595 Valve ANSI version For combination with actuators such as Type 3276 or Type 3271 Pneumatic Actuators Type 3595 Valve with Type 327...

Page 2: ...s about these instructions contact SAMSON s After sales Service Department aftersalesservice samsongroup com The mounting and operating instructions for the devices are included in the scope of delive...

Page 3: ...ed 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 4 4 4 Storage 4 5 5 Installation 5 1 5...

Page 4: ...ng the packing 9 5 9 4 3 Replacing the bellows seal 9 6 9 4 4 Lapping the seat and plug 9 7 9 5 Ordering spare parts and operating supplies 9 9 10 Decommissioning 10 1 11 Removal 11 1 11 1 Removing th...

Page 5: ...factors Refer to the technical data and nameplate for limits and fields of application as well as possible uses Reasonably foreseeable misuse The control valve is not suitable for the following applic...

Page 6: ...ty features The fail safe position of the control valve upon air supply or control signal failure depends on the actuator used see associated actuator documentation For example when the valve is combi...

Page 7: ...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 a declaration of confor...

Page 8: ...g on the process medium valve components and pipelines may get very hot or cold and cause burn injuries Allow components and pipelines to cool down or heat up Wear protective clothing and safety glove...

Page 9: ...g spring compression See associated actuator documentation Risk of personal injury due to preloaded springs Valves in combination with pneumatic actuators with preloaded springs are under ten sion Th...

Page 10: ...e plant operator is responsible for cleaning the pipelines in the plant Flush the pipelines before start up Risk of valve damage due to unsuitable medium properties The valve is designed for a process...

Page 11: ...and damage the surface Only use lubricants approved by SAMSON see the Tightening torques lubricants and tools section in the annex of these instructions Risk of contamination of the process medium th...

Page 12: ...1 8 EB 8079 EN...

Page 13: ...1 Valve nameplate The valve nameplate describes the key char acteristics of the valve such as Type designation Valve size Pressure rating Date of manufacture Serial number It is located on the valve b...

Page 14: ...2 2 EB 8079 EN Markings on the device The location of the valve nameplate varies depending on the valve size Valve body Yoke...

Page 15: ...varies depending on the mounted actuator These assemblies are fitted with an external anti rotation fixture for the plug stem The plug stem in the valve bonnet is sealed by either a PTFE or graphite...

Page 16: ...3 2 EB 8079 EN Design and principle of operation 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 Fig 3 1 Type 3595 Valve with Type 3271 Actuator...

Page 17: ...tuator with or without handwheel can be replaced by another pneumatic actuator in a different size but with the same travel Observe the maximum permissible actu ator force If the travel range of the a...

Page 18: ...ergy transfer Refer to the instructions in the Installation section Safety guard For operating conditions which require in creased safety e g in cases where the valve is freely accessible to untrained...

Page 19: ...ass IV V and VI 325 to 482 F 196 to 250 C PILOT STD PILOT LDB Leakage class V 4 to 1292 F 20 to 700 C MULTICYL Leakage class IV V and VI 325 to 482 F 196 to 250 C Table 3 2 Materials Type 3595 Globe V...

Page 20: ...00 to 1500 in On request 2 68 3 35 3 58 4 84 5 94 mm On request 68 85 91 123 151 Class 2500 in On request 2 8 On request 3 86 On request 6 26 mm On request 71 On request 98 On request 159 Height H4 Cl...

Page 21: ...1 21 34 mm 227 286 346 389 460 542 Class 2500 in 9 45 On request On request On request On request On request mm 240 On request On request On request On request On request Height H4 Class 150 to 300 in...

Page 22: ...lass 2500 in 12 13 12 13 12 52 12 52 14 13 14 25 15 75 15 87 19 61 19 84 22 64 23 03 mm 308 308 318 318 359 362 400 403 498 504 575 585 Height H2 Class 150 to 600 in On request 1 69 3 15 2 52 3 15 5 7...

Page 23: ...781 784 864 867 1016 1019 1257 1267 1422 1432 Class 1500 in 27 24 27 48 32 99 33 39 39 02 39 41 44 49 45 12 49 49 50 24 55 98 56 85 mm 692 698 838 848 991 1001 1130 1146 1257 1276 1422 1444 Class 2500...

Page 24: ...0 250 350 400 450 500 Height H8 2 Class 150 to 2500 in On request On request On request On request On request On request mm On request On request On request On request On request On request 1 H3 with...

Page 25: ...5 94 22 4 mm 231 388 405 569 Max travel in 1 02 2 01 2 99 5 00 mm 26 51 76 127 Table 3 7 Dimensions for Type 3271 Pneumatic Actuator Actuator area cm 1000 1400 60 1400 120 1400 250 2800 2 x 2800 Diaph...

Page 26: ...tion Dimensional drawings H3 H9 H H4 H2 L D D1 L H4 H8 H3 H2 H7 D a a a a H Type 3595 Globe Valve with Type 3276 Pneumatic Actuator Body with welding ends or welding neck ends Type 3595 Globe Valve wi...

Page 27: ...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 c...

Page 28: ...hoist may be used as a support when 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 va...

Page 29: ...tempera ture of standard control valves is 20 to 65 C 4 to 149 F Contact our after sales service for the trans portation temperatures of other valve ver sions Note Fig 4 1 Lifting points on the contr...

Page 30: ...e Make sure that the axis of the pipeline is always horizontal during lifting and the axis of the plug stem is always vertical Lifting the control valve 1 Attach one sling or other suitable lifting ta...

Page 31: ...ontrol 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 Place protective caps on the valve...

Page 32: ...4 6 EB 8079 EN...

Page 33: ...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 valve or to per...

Page 34: ...ugs Vent plugs are screwed into the exhaust air ports of pneumatic and electropneumatic de vices They ensure that any exhaust air that forms can be vented to the atmosphere to avoid excess pressure in...

Page 35: ...0 3 Ma 0 7 2 10 Vapor Ma 0 3 3 2 4 0 3 Ma 0 7 3 2 10 Saturated steam percentage of condensate 5 2 20 Liquid Free of cavitation w 10 m s 2 4 Cavitation producing noise w 3 m s 2 4 Cavitation producing...

Page 36: ...during installation work Flush the pipelines The plant operator is responsible for clean ing the pipelines in the plant For steam applications dry the pipelines Moisture will damage the inside of the...

Page 37: ...Support or suspend the valve sufficiently at suitable points a Version with flanges 1 Close the shut off valves in the pipeline at the inlet and outlet of the plant section while the valve is being in...

Page 38: ...efly occur through the sudden venting of the pneumatic actuator or pneumatic valve ac cessories not fitted with noise reducing fit tings Both can damage hearing Wear hearing protection when working ne...

Page 39: ...e A sudden surge in pressure and resulting high ve locities 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...

Page 40: ...alve 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 sales service c...

Page 41: ...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 moving...

Page 42: ...ng requirements see information under In tended use in the Safety instructions and measures section Start up putting the regulator back into op eration 1 Allow the valve to cool down or warm up to rea...

Page 43: ...an damage hearing Wear hearing protection when working near the valve Crush hazard arising from actuator and plug stem moving Do not insert hands or finger into the yoke while the air supply is connec...

Page 44: ...r for the packing chamber is required This lubricator is fitted with a check valve to prevent return flow into the process medium In some valves a shut off valve is additionally in stalled for better...

Page 45: ...blocking the actuator and piston stem release any stored energy in the actuator e g spring compression See associated actuator documentation Diaphragm in the actuator defective See associated actuator...

Page 46: ...cage is worn out See Replacing the gaskets in the Servicing section The valve leaks to the atmosphere fugitive emissions Defective packing See Replacing the packing in the Servicing section Version w...

Page 47: ...off valves upstream and downstream of the control valve to stop the process medium from flowing through the valve 2 Perform troubleshooting see sec tion 8 1 3 Rectify those malfunctions that can be re...

Page 48: ...8 4 EB 8079 EN...

Page 49: ...sk of burn injuries due to hot or cold com ponents 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...

Page 50: ...y can be identified by the long bolts protruding from the bottom of the actu ator Before starting any work on the actuator relieve the compression from the pre loaded springs see associated actuator d...

Page 51: ...in drawing up an inspection and test plan for your plant 9 2 Preparing the valve for service work The valve can remain installed in the pipeline and does not need to be removed to perform the service...

Page 52: ...f flow 4 Lightly press down the valve bonnet and move the plug up and down a few times to ensure that all inside parts are cen tered properly 5 Lubricate the thread of the nuts and stud bolts on the v...

Page 53: ...eplacing the packing 1 Unthread the nuts of the packing gland from the valve bonnet 2 Remove the packing gland and packing follower 3 Pull the plug stem together with the plug downwards out of the val...

Page 54: ...he stud bolts 12 Thread the nuts of the packing gland on to the stud bolts and finger tighten them clockwise in a crisscross pattern Single packing Double packing Nut Packing gland Stud Packing rings...

Page 55: ...nged Contact SAMSON s After sales Service department when reworking is required Necessary conditions for lapping In addition to preparation before performing service work the following points are re q...

Page 56: ...he weight of the plug plug stem and lapping tool create suffi cient pressure for the lapping procedure 16 Clean the seat and plug after lapping 17 To check the tight shut off of the lapped in parts ho...

Page 57: ...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 Annex for det...

Page 58: ...9 10 EB 8079 EN...

Page 59: ...EB 8079 EN 9 11...

Page 60: ...9 12 EB 8079 EN...

Page 61: ...afety gloves Risk of personal injury due to pressurized components and process medium escaping under pressure Do not loosen the screw of the test con nection while the valve is pressurized Risk of hea...

Page 62: ...residual pro cess 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 Wear protective clot...

Page 63: ...in the same position for a long time re lease any stored energy in the actuator e g spring compression See associat ed actuator documentation Risk of personal injury due to residual pro cess medium i...

Page 64: ...th welding ends 1 Support the valve to hold it in place when separated from the pipeline see the Shipment and on site transport sec tion 2 Cut the pipeline in front of the weld seam 3 Remove the valve...

Page 65: ...After sales Service 2 Send an e mail u retouren samsongroup com to regis ter the return shipment including the fol lowing information Type Article no Configuration ID Original order Completed Declarat...

Page 66: ...12 2 EB 8079 EN...

Page 67: ...EB 8079 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 68: ...13 2 EB 8079 EN...

Page 69: ...EB 8079 EN 14 1 Certificates 14 Certificates The declaration of conformity in accordance with Pressure Equipment Directive 2014 68 EU is provided on the next page...

Page 70: ...14 2 EB 8079 EN...

Page 71: ...nce NPS per inch ft lb ft lb 13 20 40 3 For 4 bolts 5 8 11 35 78 5 1 2 3 4 10 70 135 10 7 8 9 100 225 10 1 8 100 325 20 11 8 8 100 460 40 For 8 bolts 1 8 100 650 50 5 6 8 7 1 3 4 2 13 8 8 100 900 50 1...

Page 72: ...ase the en tire pin No Crane anti seize mount ing paste Plug plug stem To screw the plug stem into the plug or screwing the plug onto the plug stem Apply to the threads of the plug and plug stem No St...

Page 73: ...arts 15 3 After sales service Contact our after sales service for support concerning service or repair work or when malfunctions or defects arise E mail address You can reach our after sales service a...

Page 74: ...15 4 EB 8079 EN...

Page 75: ......

Page 76: ...2019 12 10 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 8079 EN...

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