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EB 8072 EN

8-3

Malfunctions

8.2

Emergency action

Plant operators are responsible for emergen-

cy action to be taken in the plant.
In the event of a valve malfunction:
1.

Close the shut-off valves upstream and

downstream of the control valve to stop

the process medium from flowing

through the valve.

Perform troubleshooting (see sec-
tion 8.1).

Rectify those malfunctions that can be
remedied based on the instructions pro

vided here. Contact our after-sales ser-

vice in all other cases.

Putting the valve back into operation after

a malfunction

See the 'Start-up' section.

Содержание 3291

Страница 1: ...Translation of original instructions EB 8072 EN Edition May 2021 Type 3291 Valve ANSI version In combination with an actuator e g a Type 3271 or Type 3277 Pneumatic Actuator...

Страница 2: ...st 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...

Страница 3: ...3 3 4 Valve 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...

Страница 4: ...gaskets 9 7 9 4 3 Replacing the packing 9 10 9 4 4 Replacing the seat and plug 9 13 9 4 5 Determining the number of gaskets required 9 16 9 4 6 Tightening the body nuts 9 19 9 5 Ordering spare parts...

Страница 5: ...ontrol 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...

Страница 6: ...ger meet the requirements for its intended use Safety features The fail safe position of the control valve upon air supply or control signal failure depends on the actuator used see associated actuato...

Страница 7: ...idual case and are only known to the operator Responsibilities of operating personnel Operating personnel must read and understand these mounting and operating instructions as well as the referenced d...

Страница 8: ...s for SAMSON Pneumatic Control Valves with a Declaration of Conformity of Final Machinery For oxygen service Manual u H 01 The packaging of valve constructed and sized for oxygen service has the follo...

Страница 9: ...substance which reacts quickly leading to combustion and explo sions Contact with cryogenic gases causes severe frostbite and cold burns cryogenic burns Operating personnel must be trained for these...

Страница 10: ...can injure 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...

Страница 11: ...he valve and depending on its properties cause personal injury e g chemical burns If possible drain the process medium from all the plant sections affected and the valve Wear protective clothing safet...

Страница 12: ...f valve damage due to contamination e g solid particles in the pipeline The plant operator is responsible for cleaning the pipelines in the plant Flush the pipelines before start up Risk of valve dama...

Страница 13: ...h the use of unsuitable lubri cants and or contaminated tools and components If necessary e g for oxygen service keep the valve and the tools used free from solvents and grease Make sure that only sui...

Страница 14: ...1 10 EB 8072 EN...

Страница 15: ...al 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 Ver...

Страница 16: ...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 se...

Страница 17: ...e actuator size is deter mined by the diaphragm area The process medium flows through the valve in the direction indicated by the arrow on the body in the flow to open FTO direction A rise in signal p...

Страница 18: ...3 2 EB 8072 EN Design and principle of operation 1 5 4 127 17 125 126 10 8 15 60 A26 27 14 2 124 S A10 A4 A8 A7 92 9 Fig 3 1 Type 3291 Valve with Type 3271 Pneumatic Actuator...

Страница 19: ...versed if required Refer to the mounting and operating instructions of the pneumatic actuator u EB 8310 X for Type 3271 and Type 3277 3 2 Versions With insulating section bellows seal The modular desi...

Страница 20: ...r an inspection glass Safety guard For operating conditions that require in creased safety e g in cases where the valve is freely accessible to untrained staff a safe ty guard must be installed to rul...

Страница 21: ...14 to 428 10 to 220 Up to 660 350 with high temperature packing depending on material Body with Insulating section 51 to 649 46 to 343 20 to 800 29 to 425 20 to 842 29 to 450 325 to 842 196 to 450 32...

Страница 22: ...203 210 248 283 334 384 489 584 Length L Class 600 Flanges RF welding ends schedule 80 in 8 00 8 25 9 88 11 25 13 25 15 50 20 00 24 00 mm 203 210 251 286 337 394 508 610 Flanges RTJ in 7 91 8 27 9 88...

Страница 23: ...90 18 90 mm 480 480 480 2800 cm in 18 90 18 90 18 90 mm 480 480 480 H2 NPS 4 and larger including foot Class 150 in 1 97 2 36 3 15 3 54 3 94 6 30 8 66 9 84 mm 50 60 80 90 100 160 220 250 Class 300 to...

Страница 24: ...imensions and weights u T 8072 1 The associated actuator documentation applies to actuators e g SAMSON pneumatic actu ators u T 8310 1 for Type 3271 or Type 3277 Pneumatic Actuators up to 750 cm actua...

Страница 25: ...cal data 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 Le...

Страница 26: ...Do not use this lashing point to lift the entire control valve assembly When lifting the control valve make sure that the slings attached to the valve body bear the entire load Do not attach load bear...

Страница 27: ...s e g impact Do not damage the corrosion protection paint surface coatings Repair any damage immediately Protect the piping and any mounted valve accessories against damage Protect the control valve a...

Страница 28: ...ve from tilting while being lifted Before lifting the control valve tighten the sling a Version with flanges 1 Attach one sling to each flange of the body and to the rigging equipment e g hook of the...

Страница 29: ...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 preven...

Страница 30: ...4 6 EB 8072 EN Shipment and on site transport...

Страница 31: ...personnel can perform all necessary work safely and Table 5 1 Inlet and outlet lengths a x NPS b x NPS Q Q Flow rate a Inlet length b Outlet length State of process medium Valve conditions Inlet lengt...

Страница 32: ...nstalled with the actuator on top Valves in NPS 4 and larger Valves with insulating section for low temperatures below 10 C 14 F Contact SAMSON if the mounting posi tion is not as specified above Supp...

Страница 33: ...lated it will not function 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 fol...

Страница 34: ...he 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 3 6 Use a soft fac...

Страница 35: ...the standard version Table 5 4 Tightening torques Screw size Tightening torque Nm M12 50 M16 121 13 Check and ensure the following There is a nominal clearance of 0 5 to 1 mm between the sliding washe...

Страница 36: ...1 301 309 309 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 Sliding washers Plug stem Fig 5 2 Overview of anti rotation fixture ass...

Страница 37: ...to incorrectly ap plied lubricant Do not apply any lubricant to the threads of the clamps 301 or the plug stem 6 Position the clamps 301 and stem 9 on the plug stem according to Table 5 3 and tighten...

Страница 38: ...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...

Страница 39: ...01 301 309 309 304 303 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 stem Fig 5 4 Overview of anti rotation fixture as...

Страница 40: ...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...

Страница 41: ...sion 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...

Страница 42: ...5 12 EB 8072 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...

Страница 43: ...ator stem and the stem 9 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 t...

Страница 44: ...ttern of the perforated plug and determine which hole is the closest to the seal facing and is uncovered first when the plug is lifted out of the seat On mounting the actuator make sure that the hole...

Страница 45: ...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 por...

Страница 46: ...iefly 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 n...

Страница 47: ...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 t...

Страница 48: ...the travel in dicator scale 5 4 3 Fail safe 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 P...

Страница 49: ...r pneumatic valve ac cessories not fitted with noise reducing fit tings Both can damage hearing Wear hearing protection when working near the valve Crush hazard arising from actuator and plug stem mov...

Страница 50: ...he valve 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...

Страница 51: ...atic valve ac cessories not fitted with noise reducing fit tings Both can damage hearing Wear hearing protection when working near the valve Crush hazard arising from actuator and plug stem moving Do...

Страница 52: ...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...

Страница 53: ...as the control signal Before unblocking the actuator release any stored energy in the actuator e g spring compression See associated actuator documentation Diaphragm in the actuator defective See asso...

Страница 54: ...or contact our after sales service The valve leaks to the atmosphere fugitive emissions Defective packing Replace packing see the Servicing section or contact our after sales service Version with adju...

Страница 55: ...ff 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 rem...

Страница 56: ...8 4 EB 8072 EN...

Страница 57: ...well as the valve Risk of burn injuries 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 t...

Страница 58: ...ified 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 documentation R...

Страница 59: ...n 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...

Страница 60: ...hten 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 correctly see information under Adjust...

Страница 61: ...lve See associated actuator documentation To remove an actuator with stem extends fail safe action and or with preloaded springs a certain signal pressure must be applied to the actuator see associate...

Страница 62: ...ector nut 10 Lock nut 14 Body nut 15 Packing 17 Body gasket 21 Insulating section 60 Yoke assembly 92 Castellated nut 124 Seat retainer 125 Spacer ring 126 Seat retainer gasket 127 Seat bridge gasket...

Страница 63: ...oes not have a balanced plug The valve does not have a bellows seal To replace the gaskets in other valve ver sions contact our after sales service The following gaskets are installed and must be exch...

Страница 64: ...eat retainer 124 and body 1 DF 4 Facing between the shim 125 and seat re tainer gasket 127 DF 5 Facing between the gasket 17 and shim 125 DF 6 Facing between the gasket 17 and body 1 DF 7 Facing betwe...

Страница 65: ...ening of the seat re tainer 124 faces toward the valve out let Version with V port plug place the bon net onto the valve body making sure that the largest V shaped port of the V port plug faces toward...

Страница 66: ...e lubricant to all the pack ing parts and to the plug stem 5 11 Slide the plug with plug stem 5 into the bonnet 2 12 Make sure that the seat 4 and seat re tainer 124 are still clamped correctly on the...

Страница 67: ...as described in Standard pack ing PTFE steps 15 to 18 5 Stroke the plug stem 5 up and down around ten times to allow the packing to settle c ADSEAL packing 1 Proceed as described in Standard pack ing...

Страница 68: ...9 12 16 19 12 12 12 8 19 12 16 8 12 12 11 19 16 15 15 1 15 2 12 12 18 16 18 19 8 Threaded bushing 11 Spring 12 Washer 15 Packing 15 1 Spacer ring with retaining ring 15 2 Seal 16 Packing ring 18 Space...

Страница 69: ...stem 5 off the body 1 4 Remove gaskets and replace with new ones see section 9 4 2 if necessary 5 Unscrew the stem connector nut 9 and lock nut 10 from the plug stem 6 Unscrew the threaded bushing 8 7...

Страница 70: ...ble tool Observe the proper sequence see Fig 9 6 19 Firmly press the plug 5 into the seat 4 Fasten down the bonnet 2 with the body nuts 14 See section 9 4 6 20 Screw in the threaded bushing 8 and tigh...

Страница 71: ...EB 8072 EN 9 15 Servicing 1 5 4 127 17 125 126 10 8 15 60 A26 27 14 2 124 S A10 A4 A8 A7 92 9 Fig 9 7 Type 3291 Valve with Type 3271 Pneumatic Actuator...

Страница 72: ...evenly dis tributed around the circumference of the body 2 Write down the measured values 1 to 3 in Table 9 1 Calculate the average value and enter it as H1actual 3 Calculate the difference H from th...

Страница 73: ...own the measured values 1 to 3 in Table 9 2 Calculate the average value and enter it as H2actual 3 Insert the gasket 126 See sec tion 9 4 2 124 1 126 126 H2 1 Body 4 Seat 124 Seat retainer 126 Seat re...

Страница 74: ...ght ttotal based on the previously determined values see Table 9 1 and Table 9 2 and enter it into Ta ble 9 3 2 Insert shims 125 See section 9 4 2 Use only one shim and one gasket to com pensate for t...

Страница 75: ...ce as the gasket 126 underneath the shim 125 yields On tightening the body nuts on the bonnet 2 or insulating section 21 proceed as follows 1 Tighten the body nuts gradually in a crisscross pattern ap...

Страница 76: ...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 det...

Страница 77: ...protective 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 pres...

Страница 78: ...hile 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 Wear protective clothing safety gloves respiratory protec...

Страница 79: ...energy in the actuator e g spring compression See associat ed actuator documentation Risk of personal injury due to residual process medium in the valve While working on the valve residual me dium can...

Страница 80: ...ipeline a Version with flanges 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 fro...

Страница 81: ...rt 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 Decla...

Страница 82: ...12 2 EB 8072 EN...

Страница 83: ...EB 8072 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...

Страница 84: ...13 2 EB 8072 EN...

Страница 85: ...Types 3291 1 and 3291 7 Control Valves on page 14 3 Declaration of incorporation in compliance with Machinery Directive 2006 42 EC for the Type 3291 Valve with other actuators other than Types 3271 an...

Страница 86: ...14 2 EB 8072 EN...

Страница 87: ...EB 8072 EN 14 3...

Страница 88: ...14 4 EB 8072 EN...

Страница 89: ...lity of shim material Tip Table 15 1 Item numbers to order shims Shim material NPS Item no 1 4404 A240 316L to 1 1120 3074 1 1120 3075 2 1120 3076 3 1120 3077 4 1120 3078 6 1120 3079 8 1120 3136 1 430...

Страница 90: ...th metal bellows 39 Gasket bonnet 42 Screw plug test connection 43 Seal 44 Ring pressure balancing 45 Gasket pressure balancing 46 Gasket pressure balancing 47 Support pressure balancing 48 Hex screw...

Страница 91: ...EB 8072 EN 15 3 Annex...

Страница 92: ...15 4 EB 8072 EN 82 10 92 3 84 83 81 85 80 9 5 8 15 16 16 19 19 12 11 12 14 2 7 7 14 21 17 125 126 46 50 53 53 48 51 49 50 44 52 45 46 47 48 51 5 102 45 44 47 81 26 10 92 3 9 84 83 81 80 60 60 85...

Страница 93: ...EB 8072 EN 15 5 4 13 127 1 91 13 124 29 29 6 28 27 31 34 37 39 17 125 126 24 22 14 33 32 101 39 42 43 7 81 80 81 26 8 15 19 12 11 124 16...

Страница 94: ...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...

Страница 95: ......

Страница 96: ...2021 10 18 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 8072 EN...

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