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8-2

EB 8061 EN

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.

2. Perform troubleshooting (see sec-

tion 8.1).

3. 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.

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

: packing not

tightened correctly

Adjust the packing (see information under

'Adjusting the packing' in the 'Installation' section >

'Testing the installed valve'). Contact our after-sales

service when it continues to leak.

Version with bellows

seal: the bellows seal is

defective.

Contact our after-sales service.

Flange joint loose or

gasket worn out

Check the flange joint.

Replace gasket at the flanged joint (see the

'Servicing' section) or contact our after-sales

service.

See the 'Markings on the device' section.

Contact our after-sales service for malfunctions not listed in the table.

Note

Содержание EB 8061 EN

Страница 1: ...on of original instructions EB 8061 EN Type 3254 Valve ANSI version In combination with an actuator e g a Type 3271 or Type 3277 Pneumatic Actuator Edition January 2021 Type 3254 Valve with Type 3271...

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 Additional fittings 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...

Страница 4: ...eplacing the top gasket 9 7 9 4 2 Replacing the bottom gasket 9 8 9 4 3 Replacing the packing 9 9 9 4 4 Replacing the seat and plug 9 14 9 5 Ordering spare parts and operating supplies 9 16 10 Decommi...

Страница 5: ...meplate for limits and 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 duri...

Страница 6: ...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...

Страница 7: ...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 stateme...

Страница 8: ...very high concern on the candidate list of the REACH regulation Information on safe use of the part affected u www samsongroup com About SAMSON Material Compliance REACH If a device contains a substan...

Страница 9: ...Install the control valve in such a way that vent openings are not located at eye level and the actuator does not vent at eye level in the work position Use suitable silencers and vent plugs Wear eye...

Страница 10: ...ut of the 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 clothin...

Страница 11: ...valve components Excessive tightening torques lead to parts wearing out more quickly Parts that are too loose may cause leakage Observe the specified tightening torques u AB 0100 Risk of valve damage...

Страница 12: ...in potentially explosive atmospheres Do not expose the RFID tag to strong electric fields Avoid electrostatic charging Observe the application range technical specifications of the RFID tag 1 5 Warnin...

Страница 13: ...seal 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 V...

Страница 14: ...aterial 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...

Страница 15: ...in the seat changes and determines the flow rate through the valve We recommend the use of positioners with integrated diagnostic firmware see sec tion 3 4 for valves used for on off service The parti...

Страница 16: ...aded bushing packing nut 9 Stem connector nut 10 Lock nut 14 Nut 15 Packing 17 Body gasket 84 Travel indicator scale 92 Castellated nut 100 Flange A4 Diaphragm A7 Actuator stem A8 Ring nut A10 Spring...

Страница 17: ...om damaging the valve Bypass and shut off valves We recommend installing a shut off valve both upstream of the strainer and down stream of the valve and installing a bypass line The bypass ensures tha...

Страница 18: ...bellows seal can ex tend the temperature range from 196 to 550 C 325 to 1022 F depending on the properties of the materials used Leakage class Depending on the version the following leakage class appl...

Страница 19: ...3254 Standard version Table 3 1 1 Valve size NPS 3 to 8 DN 80 to 200 Valve NPS 3 4 6 8 DN 80 100 150 200 Length L flanges RF and weld ing ends Class 150 in 11 75 13 88 17 75 21 38 mm 298 352 451 543 C...

Страница 20: ...H8 for actuator 1400 60 cm in 11 61 11 61 16 46 16 46 mm 295 295 418 418 1400 120 cm in 18 90 18 90 19 80 19 80 mm 480 480 503 503 2800 cm in 18 90 18 90 19 80 19 80 mm 480 480 503 503 2x2800 cm in 1...

Страница 21: ...0 in 33 00 38 00 44 50 On request mm 838 965 1130 Class 1500 in 39 00 44 50 54 50 On request mm 991 1130 1384 Class 2500 in 50 00 56 00 mm 1270 1422 Height H4 Class 150 to 600 in 17 41 1 25 79 25 20 3...

Страница 22: ...ass 300 to 600 in 16 14 18 90 25 59 28 94 mm 410 480 650 735 Class 900 in 16 14 18 90 On request mm 410 480 Class 1500 in 26 77 29 92 On request mm 680 760 Class 2500 in On request mm 1 NPS 10 in Clas...

Страница 23: ...lbs 196 287 785 1323 2509 3417 6173 On req kg 89 130 356 600 1138 1550 2800 Class 900 lbs 196 287 785 1415 3009 3902 6834 On req kg 89 130 356 642 1365 1770 3100 Class 1500 lbs On request kg Class 250...

Страница 24: ...Table 3 2 2 Valve size NPS 10 to 20 DN 250 to 500 Valve size NPS 10 12 16 20 DN 250 300 400 500 Height H4 Class 150 to 600 in 42 01 45 32 44 76 On request mm 1067 1151 1137 Class 900 in 42 01 On reque...

Страница 25: ...18 34 02 On request mm 30 864 in 2 36 On re quest mm 60 Class 2500 in 0 59 40 16 On request mm 15 1020 in 1 18 40 16 On request mm 30 1020 in 2 36 On re quest mm 60 Class 150 to 300 in 1 18 to 4 72 41...

Страница 26: ...o 300 in 1 18 to 4 72 59 13 60 20 59 69 62 60 mm 30 to 120 1502 1529 1516 1590 Class 600 to 900 in 1 18 to 2 36 62 68 64 96 On request mm 30 to 60 1592 1650 Class 600 in 4 72 94 65 91 42 90 16 On re q...

Страница 27: ...tion 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 actuator area u T 8310 2 for Type 3271 Actuator with 1000 cm actuator a...

Страница 28: ...3 14 EB 8061 EN...

Страница 29: ...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...

Страница 30: ...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...

Страница 31: ...sions 4 3 2 Lifting the valve To install a large valve into the pipeline use lifting equipment e g crane or forklift to lift it Lifting instructions Use a hook with safety latch see Fig 4 1 to secure...

Страница 32: ...quipment 3 Carefully lift the control valve Check whether the lifting equipment and acces sories can bear the weight 4 Move the control valve at an even pace to the site of installation 5 Install the...

Страница 33: ...lve 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 of a...

Страница 34: ...4 6 EB 8061 EN...

Страница 35: ...nformation under Mounting posi tion and Support or suspension in this section Install the valve allowing sufficient space to remove the actuator and valve or to perform service work on them Mounting p...

Страница 36: ...e not damaged The valve data on the nameplate type designation valve size material pres sure rating and temperature range match the plant conditions size and Table 5 1 Inlet and outlet lengths Q a x N...

Страница 37: ...and tools to have them ready 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 w...

Страница 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 fa...

Страница 39: ...255 Warning label 310 Ball bearing Plug 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...

Страница 40: ...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 41: ...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 4 and tighten...

Страница 42: ...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 43: ...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 44: ...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 45: ...6 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 NPS 10 seat bore 250 and NP...

Страница 46: ...5 12 EB 8061 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 47: ...tor 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 th...

Страница 48: ...check the hole pattern 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 s...

Страница 49: ...se 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...

Страница 50: ...riefly occur through the sudden venting of the pneumatic actuator or pneumatic valve accessories not fitted with noise reducing fittings Both can damage hearing Wear hearing protection when working ne...

Страница 51: ...re 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...

Страница 52: ...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 responsible for per forming the pressure test...

Страница 53: ...position 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...

Страница 54: ...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...

Страница 55: ...ator or 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 st...

Страница 56: ...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 57: ...ion 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 actua...

Страница 58: ...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...

Страница 59: ...s 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...

Страница 60: ...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 61: ...g the packing in the Installation section Testing the installed valve If the packing leaks continuously replace the packing see section 9 4 3 The control valve was checked by SAMSON before it left the...

Страница 62: ...e 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 correctly see in...

Страница 63: ...B 8061 EN 9 5 Servicing 9 10 8 92 3 2 5 4 15 14 17 1 100 7 17 14 7 21 13 93 14 Fig 9 1 Standard version of Type 3254 with Type 3271 Actuator left and Type 3254 in version with insulating section right...

Страница 64: ...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 sa...

Страница 65: ...see Testing the installed valve in the Installation section 9 4 1 Replacing the top gasket Risk of control valve damage due to incor rect servicing The gasket can only be replaced when all the followi...

Страница 66: ...e plug that releases the flow first faces to ward the valve outlet See relevant information under Mount ing the actuator onto the valve in the In stallation section 6 Firmly press the plug 5 into the...

Страница 67: ...ug 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 lubricant to all...

Страница 68: ...packing chamber us ing a suitable tool Observe the proper sequence see Fig 9 3 3 Slide the seals 15 2 over the plug stem Insert the wire of the red spacer ring 15 1 into the groove of the retaining r...

Страница 69: ...ng section 21 and plug with plug stem 5 off the body 1 4 Unscrew the stem connector nut 9 and lock nut 10 from the plug stem 5 Unscrew the threaded bushing 8 8 12 12 11 19 16 15 15 1 15 2 12 12 18 16...

Страница 70: ...2 Carefully slide the packing parts over the plug stem into the packing chamber us ing a suitable tool Observe the proper sequence see Fig 9 2 13 Firmly press the plug 5 into the seat 4 Fasten down th...

Страница 71: ...B 8061 EN 9 13 Servicing 9 10 8 92 3 2 5 4 15 14 17 1 100 7 17 14 7 21 13 93 14 Fig 9 4 Standard version of Type 3254 with Type 3271 Actuator left and Type 3254 in version with insulating section righ...

Страница 72: ...in other valve versions contact our after sales service Risk of damage to the facing of the seat and plug due to incorrect servicing Always replace both the seat and plug When replacing the seat and p...

Страница 73: ...Firmly press the plug 5 into the seat 4 Fasten down the bonnet 2 with the top body nuts 14 Tighten the nuts gradual ly in a crisscross pattern Observe tight ening torques 18 Screw in the threaded bush...

Страница 74: ...e actuator onto the valve in the In stallation section 16 Carefully slide the packing parts over the plug stem extension into the packing chamber using a suitable tool Observe the proper sequence see...

Страница 75: ...ear 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 p...

Страница 76: ...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 Wear protective clothing safety gloves respiratory prote...

Страница 77: ...tored 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 medium...

Страница 78: ...the pipeline 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 valv...

Страница 79: ...pport 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 Decl...

Страница 80: ...12 2 EB 8061 EN...

Страница 81: ...EB 8061 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 82: ...13 2 EB 8061 EN...

Страница 83: ...C for Types 3254 1 and 3254 7 Control Valves on page 14 3 Declaration of incorporation in compli ance with Machinery Directive 2006 42 EC for the Type 3254 Valve with other actuators other than Types...

Страница 84: ...14 2 EB 8061 EN...

Страница 85: ...EB 8061 EN 14 3...

Страница 86: ...14 4 EB 8061 EN...

Страница 87: ...EB 8061 EN 15 1 Annex 15 Annex 15 1 Tightening torques lubri cants and tools u AB 0100 for tools tightening torques and lubricants...

Страница 88: ...h metal bellows 39 Gasket 42 Screw plug with seal 44 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 ver sion with...

Страница 89: ...1 92 83 32 84 85 82 3 9 10 8 16 16 12 12 12 19 16 12 12 19 11 12 11 19 15 94 37 39 7 101 33 14 93 39 22 2 21 14 93 81 7 5 26 7 24 27 28 29 5 34 31 14 93 26 81 15 5 102 48 51 47 53 44 52 45 50 46 49 50...

Страница 90: ...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 91: ......

Страница 92: ...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 8061 EN...

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