Samson BR 20a Mounting And Operating Instructions Download Page 4

EB 20a_EN

November 2023 edition

Subject to technical changes

Content

6 Start 

up 

6-1

7 Operation 

7-1

8 Malfunction 

8-1

8.1 

Detecting and rectifying errors 

8-1

8.2 

Carrying out emergency measures 

8-2

9 Servicing 

9-1

9.1 Periodic 

tests 

9-1

9.2 Maintenance 

work 

9-2

9.2.1 

Replacing the seal rings and ball 

9-2

9.3 

Ordering spare parts and consumables 

9-2

10 Decommissioning 

10-1

11 Removal 

11-1

11.1  Removing the ball valve from the pipe 

11-1

11.2  Disassembling the actuator 

11-1

12 Repairs 

12-1

12.1  Replacing the V-ring packing in the case of a DIN ball valve 

12-1

12.1.1 

Ball valve in the “standard version” 

12-1

12.1.2 

Ball valve with “double stuf

fi

 ng box” 

12-1

12.2  Replacing the V-ring packing in the case of a ANSI ball valve 

12-3

12.3  Replacing the seat ring of the ball 

12-3

12.4  Additional repairs  

12-3

12.5  Sending devices to PFEIFFER 

12-4

13 Disposal 

13-1

14 Certi

fi

 cates 

14-1

15 Annex 

15-1

15.1  Tightening torques, lubricant and tools 

15-1

15.1.1 Tightening 

torques 

15-1

15.1.2 Lubricant 

15-2

15.1.3 Tools 

15-2

15.2 Spare 

parts 

15-2

15.2.1 

Spare parts of the ball valve in the DIN version, DN 15 ... 100 

15-3

15.2.2 

Spare parts of the ball valve in the DIN version, DN 150 ... 200 

15-4

15.2.3 

Spare parts of the ball valve in the ANSI version 

15-5

15.2.4 

Spare parts of the ball valve with double stuf

fi

 ng box 

15-6

15.3 Service 

15-7

Summary of Contents for BR 20a

Page 1: ...Phone 02152 2005 0 Fax 02152 1580 sales pfeiffer de samsongroup com www pfeiffer armaturen com MOUNTING AND OPERATING INSTRUCTIONS EB 20a Translation of the original manual Ball valve BR 20a DIN and...

Page 2: ...safe and correct use read this EB carefully prior to use and keep it for later reference In the case of questions that go beyond the scope of this EB please contact the After Sales Service at PFEIFFE...

Page 3: ...2 Assembly of the DIN ball valve DN 150 200 3 4 3 5 3 Assembly of the ANSI ball valve 3 6 4 Shipment and on site transport 4 1 4 1 Accepting delivery 4 1 4 2 Unpacking the ball valve 4 1 4 3 Transpor...

Page 4: ...12 1 1 Ball valve in the standard version 12 1 12 1 2 Ball valve with double stuffing box 12 1 12 2 Replacing the V ring packing in the case of a ANSI ball valve 12 3 12 3 Replacing the seat ring of t...

Page 5: ...onnel The ball valve may only be disassembled dismantled assembled and commissioned by qualified specialist personnel trained in pressurised pipes who are familiar with the assembly commis sioning and...

Page 6: ...s in po tentially explosive areas Ball valves with plastic lining PFA PTFE EPDM etc through which chargeable media flows during operation must be provided with an electrostatically dissipative plastic...

Page 7: ...s media spraying medium can cause hazards It must be kept in mind that the media is usually hazardous A blind flange must be assembled on the free connecting pieces or the ball valve must be secured a...

Page 8: ...ble tools can damage the ball valve Suitable tools are required to work on the ball valve see Chapter 15 1 3 Tools Damage to the ball valve due to unsuitable lubricants Unsuitable lubricants can corro...

Page 9: ...missible op erating pressure PS and number value 7 Test pressure PT and number value The test pressure must be observed depending on the device 8 Manufacturer number from 2018 e g 381234 001 001 38 12...

Page 10: ...or DN 15 25 and NPS 1 Figure 2 2 Type plate 82149ae for DN 40 200 and NPS1 8 2 1 2 Actuator type plate See the corresponding actuator documentation 2 2 Material marking The ball valves are marked on t...

Page 11: ...he BR 20a ball valve can be selected in the following versions With a hand lever DN 15 up to 100 or NPS1 up to 4 With a manual gear With PFEIFFER rotary actuator BR 31a With rotary actuators from othe...

Page 12: ...lve material requires suitable lubricant A suitable lubri cant must be selected for grease free ball valves especially for use with oxygen For suitable lubricant see Chapter 15 1 2 Lubricant Info NOTE...

Page 13: ...the DIN version DN 15 100 Item Designation Item Designation 1 Lined body 18 O ring 2 Lined ball 19 Stuffing box lower section 3 Seat ring 20 Distance bush 4 Screw stud bolt 21 Disc spring set 5 Nut 22...

Page 14: ...the body halves 1a and 1b The seat rings may not be installed without clearance To achieve the tightness of the ball valve the seat rings must be installed in their seat with sufficient clearance If...

Page 15: ...version DN 150 200 Table 3 2 Parts list of the ball valve in the DIN version DN 150 200 Item Designation Item Designation 1 Lined body 11 Stuffing box flange 2 Lined ball 12 Screw 3 Seat ring 14 Centr...

Page 16: ...the stuffing box flange 11 Place the pre assembled stuffing box flange on the body and adjust with screws 12 Tighten the screws evenly in a criss cross pattern until a gap between 1 2 mm has formed b...

Page 17: ...n the ANSI version Table 3 3 Parts list of the ball valve in the ANSI version Item Designation Item Designation 1 Lined body 11 Stuffing box flange 2 Lined ball 12 Screw 3 Seat ring 14 Centring ring 4...

Page 18: ...see Fig 3 3 Place the centring ring 14 on the disc spring s Insert the disc spring set 9 in the centring ring until reaching the bottom ring of the V ring packing The arrangement and quantity of the d...

Page 19: ...d approved lifting equipment and load lifting equip ment whose lifting capacity corresponds at least to the weight of the ball valve including the actuator Take the weights from the respective data sh...

Page 20: ...e as examples for most valve variants On site the conditions for lifting and transporting the valve can change how ever The operator makes sure that the valve is lifted and transport ed safely WARNING...

Page 21: ...torage prior to installation the ball valve should normally be stored in a closed room where it is pro tected against harmful influences such as impacts dirt or moisture A room temperature of 25 C 15...

Page 22: ...4 4 EB 20a_EN November 2023 edition Subject to technical changes Shipment and on site transport...

Page 23: ...st air can be released to the outside protection against over pressure in the device Furthermore vents allow the intake of air protection against underpressure in the device Carry out venting on the s...

Page 24: ...permissible pressure temperature range is not sufficient for the max permissible operating conditions The limits of use are marked on the ball valve see Chapter 2 Markings on the device The permissib...

Page 25: ...fix the deformation of the pipes Screw the pipe together with the ball valve without tension After installing the ball valve open it slowly in the pipe Damage to the ball valve due to a sudden pressu...

Page 26: ...it and control command see chapter 8 Faults 5 5 2 Pressure test of the pipe section The pressure test was already performed on the ball valves by PFEIFFER Observe the following for the pressure test o...

Page 27: ...the corresponding actuator docu mentation Prior to disassembly of the actuator bring the ball valve into the fail safe position Danger of injury due to escaping exhaust air During operation when regu...

Page 28: ...6 2 EB 20a_EN November 2023 edition Subject to technical changes Start up...

Page 29: ...escape for example from the ac tuator Wear eye protection and if necessary hearing protection when working near valves Observe the following points during operation The PTFE plastic sealing surfaces...

Page 30: ...7 2 EB 20a_EN November 2023 edition Subject to technical changes Operation...

Page 31: ...ange seals If the seals are damaged replace them Leaks in the body parts The body section connection loosened Retighten the body halves with the respective tightening torque see Table 15 1 in Chapter...

Page 32: ...ot listed in the table contact the After Sales Service at PFEIFFER Spare parts must be ordered indicating all the data according to the valve marking Only original parts from PFEIFFER Che mie Armature...

Page 33: ...e and depending on the medium properties cause injuries e g scalding chemical burns Wear protective garments protective gloves and eye protec tion Do not loosen the screw of the optional test connecti...

Page 34: ...determine the cause and remedy it see Chapter 8 Malfunctions Check pipe connections and seals of the ball valve and actu ator for leaks Regular maintenance work on the ball valve is not necessary but...

Page 35: ...al energy of the actuator spring tension before re leasing the blockage see the corresponding actuator docu mentation Prior to disassembly of the actuator bring the ball valve into the fail safe posit...

Page 36: ...10 2 EB 20a_EN November 2023 edition Subject to technical changes Decommissioning...

Page 37: ...esidual medium can escape and depending on the medium properties cause injuries e g scalding chemical burns Wear protective garments protective gloves and eye protec tion Do not loosen the screw of th...

Page 38: ...11 2 EB 20a_EN November 2023 edition Subject to technical changes Removal...

Page 39: ...g 7 Check the PTFE rings of the V ring packing as well as all plastic parts for damage and in the case of doubt replace them Assemble the ball valve as described in Chapter 3 5 1 DIN ball valve assemb...

Page 40: ...12 2 EB 20a_EN November 2023 edition Subject to technical changes Repairs Figure 12 1 BR 20a ball valve...

Page 41: ...at rings may not be installed without clearance To achieve the tightness of the ball valve the seat rings must be installed in their seat with sufficient clearance If this is not possible please conta...

Page 42: ...t be accepted PFEIFFER recommends documenting the following contamina tion data in the form FM 8 7 6 Declaration regarding the contamination of PFEIFFER valves and components This form is available at...

Page 43: ...r 2023 edition Subject to technical changes Disposal 13 Disposal For disposal observe the local national and international regulations Do not dispose of old components lubricant and hazardous material...

Page 44: ...13 2 EB 20a_EN November 2023 edition Subject to technical changes Disposal...

Page 45: ...ure Equipment Directive 2014 68 EU for manually operated valves see page 14 3 Declaration of conformity for completed machinery accord ing to Machinery Directive 2006 42 EC for the ball valve with act...

Page 46: ...14 2 EB 20a_EN November 2023 edition Subject to technical changes Certificates...

Page 47: ...14 3 EB 20a_EN November 2023 edition Subject to technical changes Certificates...

Page 48: ...14 4 EB 20a_EN November 2023 edition Subject to technical changes Certificates...

Page 49: ...14 5 EB 20a_EN November 2023 edition Subject to technical changes Certificates...

Page 50: ...14 6 EB 20a_EN November 2023 edition Subject to technical changes Certificates...

Page 51: ...and 9 35 Nm DN 50 NPS2 1 to 7 25 Nm 8 and 9 30 Nm DN 80 NPS3 1 to 13 35 Nm 14 and 15 40 Nm DN 100 NPS4 1 to 14 35 Nm 15 and 16 45 Nm DN 150 NPS6 1 to 12 40 Nm 13 and 14 45 Nm DN 200 NPS8 1 to 14 50 Nm...

Page 52: ...1 3 Tools Suitable tools are required to work on the ball valve Unsuitable tools can damage the ball valve 15 2 Spare parts PFEIFFER recommends spare part sets for Commissioning and for 2 year operat...

Page 53: ...he ball valve in the DIN version DN 15 100 Pos Designation Material In the spare parts set for commissioning In the spare parts for 2 year operation 1 Lined body EN JS 1049 PTFE 2 Lined ball 1 4313 PT...

Page 54: ...150 200 Pos Designation Material In the spare parts set for commissioning In the spare parts for 2 year operation 1 Lined body EN JS 1049 PTFE 2 Lined ball 1 4313 PFA 3 Seat ring PTFE 4 Stud screw A4...

Page 55: ...signation Material In the spare parts set for commissioning In the spare parts for 2 year operation 1 Lined body EN JS 1049 PTFE 2 Lined ball 1 4313 PFA 3 Seat ring PTFE 4 Stud screw A4 70 5 Nut A4 70...

Page 56: ...6 EB 20a_EN November 2023 edition Subject to technical changes Annex 15 2 4 Spare parts of the ball valve with double stuffing box Figure 15 5 Exploded drawing of the ball valve with double stuffing b...

Page 57: ...g 1 4305 PTFE 24 O ring Viton 25 Stuffing box upper section 1 4301 26 Screw A2 70 27 Screw plug 1 4571 28 Washer A4 15 3 Service For maintenance and repair work as well as malfunctions or defects cont...

Page 58: ...n The indicated data sheets and further information are available also in English at the following address PFEIFFER Chemie Armaturenbau GmbH Hooghe Weg 41 47906 Kempen Germany Phone 49 2152 2005 0 Fax...

Page 59: ...EB 20a_EN November 2023 edition Subject to technical changes...

Page 60: ...3 edition Subject to technical changes PFEIFFER Chemie Armaturenbau GmbH Hooghe Weg 41 47906 Kempen Germany Phone 49 2152 2005 0 Fax 49 2152 1580 E Mail sales pfeiffer de samsongroup com Internet www...

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