Samson 3248-1 Service-Handbuch

Pneumatic Control Valve

Type 3248-1 and Type 3248-7

Mounting and

Operating Instructions

EB 8093 EN

Edition September 2008

Fig. 1 · Type 3248 as globe-pattern valve and angle-pattern valve, both fitted with Type 3277 Pneumatic Actuator

Contents Page

1 Design and principle of operation . . . . . . . . . . . . . . . . . . . 4

2 Assembling and adjusting valve and actuator. . . . . . . . . . . . . . . 6

2.1 Option to pretension the springs for actuator version

"Actuator stem extends" . . . . . . . . . . . . . . . . . . . . . . . . 7

2.2 Valve and actuator that have different rated travels . . . . . . . . . . . 7

3 Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

3.1 Mounting position . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

3.2 Signal pressure line. . . . . . . . . . . . . . . . . . . . . . . . . . . 8

4 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

5 Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

5.1 Replacing packing, seat, and plug . . . . . . . . . . . . . . . . . . . 9

6 Version with split plug stem extension. . . . . . . . . . . . . . . . . 11

7 Customer inquiries . . . . . . . . . . . . . . . . . . . . . . . . . . 13

2EB 8093 EN

Contents

Note:

Non-electrical actuators and valves do not have their own potential ignition source

according to the risk assessment in the rare incident of an operating fault, corresponding to

EN 13463-1: 2001 paragraph 5.2, and therefore do not fall within the scope of the

European Directive 94/9/EC.

Refer to paragraph 6.3 of EN 60079-14:1977 VDE 0165 Part 1 concerning connection to

equipotential bonding system.

EB 8093 EN 3

Safety instructions

General safety instructions

The control valve may only be mounted, started up or serviced by fully

trained and qualified personnel, observing the accepted industry codes and

practices. Make sure employees or third persons are not exposed to any

danger. All safety instructions and warnings in these mounting and

operating instructions, particularly those concerning assembly, start-up and

maintenance, must be observed.

The control valves fulfill the requirements of the European Pressure

Equipment Directive 97/23/EC. Valves with a CE marking have a

declaration of conformity that includes information about the applied

conformity assessment procedure.

The corresponding declaration of conformity can be viewed and

downloaded on the Internet at http://www.samson.de.

For appropriate operation, make sure that the control valve is only used in

areas where the operating pressure and temperatures do not exceed the

operating values which are based on the valve sizing data submitted in the

order. The manufacturer does not assume any responsibility for damage

caused by external forces or any other external influence!

Any hazards which could be caused in the control valve by the process

medium, operating pressure, signal pressure or by moving parts are to be

prevented by means of the appropriate measures.

Proper shipping and appropriate storage of the control valve are assumed.

Caution!

For installation and maintenance work on the valve, make sure the relevant

section of the pipeline is depressurized and, depending on the process

medium, drained as well. If necessary, allow the control valve to cool down

or warm up to reach ambient temperature prior to starting any work on the

valve.

Prior to performing any work on the valve, make sure the supply air and

control signal are disconnected or blocked to prevent any hazards that

could be caused by moving parts.

Special care is needed for pneumatic control valves when the actuator

springs are pretensioned. These actuators are labeled correspondingly and

can also be identified by three long bolts protruding from the bottom of the

actuator. Prior to starting any work on the control valve, relieve the

compression from the pretensioned springs.

1 Design and principle of

operation

The Type 3248 Cryogenic Valve can be

combined with either a Type 3271 or a

Type 3277 Pneumatic Actuator with integral

positioner attachment.

The globe-pattern or angle-pattern valve

body is designed for welding in vacuum-in-

sulated pipelines or for installation in

cold-box applications.

The cryogenic extension bonnet consists of a

metal bellows located directly above the

valve body and the insulating section above

the bellows seal.

The test connection (4.4) allows the pressure

to be monitored in order to check for leak-

age of the metal bellows.

The process medium flows through the valve

in the direction indicated by the arrow. The

position of the plug (3) is determined by

changes in the signal pressure acting on the

actuator diaphragm.

The stem connector (7) connects the plug

stem (6) with attached plug (3) and actuator

stem (8.1).

The plug stem is sealed by the metal bellows

and the backup stuffing box (4) with

spring-loaded PTFE-carbon V-ring packing

(4.2).

Fail-safe position:

Depending on how the springs (8.3) are ar-

ranged in the actuator, the control valve as-

sumes two different fail-safe positions:

Actuator stem extends:

When the pressure is relieved or the supply

air fails, the actuator springs move the actu-

ator stem downwards and close the valve.

Actuator stem retracts:

When the pressure is relieved or the supply

air fails, the actuator springs move the actu-

ator stem upwards and open the valve.

4EB 8093 EN

Design and principle of operation

Legend to Fig. 2

1 Valve body

1.1 Cryogenic extension bonnet

1.3 Nuts

2 Seat

3 Plug

4.1 Spring

4.2 Packing

4.3 Washer

4.4 Test connection

5 Valve bonnet

5.1 Guide bushing

5.2 Threaded bushing

5.3 Nuts

5.4 Travel scale indicator

5.5 Seal

6 Plug stem

6.1 Stem connector nut

6.2 Lock nut

6.3 Plug stem extension with metal bellows

6.3a and 6.3b with split extension bonnet

6.4 Bellows nut

6.5 Bellows flange

6.6 Guide bushing

(not with NPS 4 and 6/Class 150 - 300,

version with split plug stem extension)

6.7 Nut(s)

6.8 Washers

7 Stem connector

8 Actuator

8.1 Actuator stem

8.2 Annular nut

8.3 Springs

8.4 Rollng diaphragm

9 Loading pressure connection

10 Venting plug

EB 8093 EN 5

Design and principle of operation

Fig. 2 · Sectional drawings

Top section (6.3a)

Nut

Bottom section (6.3b)

Version with split

plug stem extension,

refer to section 6

Type 3271 Actuator Type 3277 Actuator

Globe valve

Aluminum

angle valve

2 Assembling and adjusting

valve and actuator

If the valve and actuator have not been pre-

assembled by the manufacturer or in the

case that the original actuator attached to

the valve is to be replaced by another actua-

tor of a different type or size, proceed as

follows:

Removing a mounted actuator

Note!

For actuators with fail-safe action "Actuator

stem extends" and especially actuators with

pretensioned springs, apply a pressure

slightly higher than the lower signal pressure

range (see actuator nameplate) to the

loading pressure connection on the bottom

diaphragm chamber, before loosening the

annular nut (8.2).

4Remove clamps of the stem connector (7)

between the actuator and plug stem ex-

tension and unscrew annular nut (8.2).

4Lift the actuator off the valve.

Mounting the actuator

1. Loosen the lock nut (6.2) and stem con-

nector nut (6.1) on the valve. Firmly

press the plug with the plug stem into the

seat. Then thread down the lock nut and

stem connector nut.

2. Remove clamps of the stem connector (7)

and annular nut (8.2) on the actuator

(8).

3. Slide the annular nut over the plug stem

extension.

4. Place the actuator on the valve bonnet

(5) and screw tight using the annular nut

(8.2).

5. Read the nameplate on the actuator to

determine which bench range (signal

range with pretensioned springs) and

which operating mode of the actuator

are used.

The operating mode (fail-safe action) "Actu-

ator stem extends" or "Actuator stem re-

tracts" is indicated on the nameplate by FA

or FE on the Type 3271 Actuator and by the

appropriate symbol on the Type 3277 Actu-

ator.

The lower bench range corresponds to the

lower signal pressure range to be adjusted;

the upper bench range corresponds to the

upper signal pressure range.

6. For actuators with fail-safe action "Actu-

ator stem extends", apply the pressure

corresponding to the lower signal pres-

sure range (e.g. 0.2 bar) to the loading

pressure connection on the bottom dia-

phragm chamber.

For actuators with fail-safe action "Actu-

ator stem retracts", apply the pressure

corresponding to the upper signal pres-

sure range (e.g. 1 bar) to the loading

pressure connection on the top dia-

phragm chamber.

7. Manually turn the stem connector nut

(6.1) until it touches the actuator stem

(8.1) and then turn it a further 1/4 turn.

Screw tight the lock nut (6.2) while hold-

ing the stem connector nut stationary to

6EB 8093 EN

Assembling and adjusting valve and actuator

ensure that the plug stem extension (6.3)

with the metal bellows is not twisted.

8. Position clamps of the stem connector (7)

and fasten

9. Align travel indicator scale (5.4) with tip

of the stem connector; for actuators with

"Actuator stem extends" align it with

lower marking (valve closed) and for ac-

tuators with "Actuator stem retracts"

align it with top marking (valve open).

2.1 Option to pretension the

springs for actuator version

"Actuator stem extends"

To achieve a greater thrust, the springs of

actuators can be pretensioned by 12.5 %

(240 cm²), by 25 % (350 and 700 cm²) or

by 75 % (700 cm²) of their travel or their

bench range.

If, with a bench range of 0.2 to 1 bar, the

springs are to be pretensioned by 0.1 bar,

for example, the bench range is shifted by

0.1 bar to 0.3 bar.

When adjusting the valve, a signal pressure

of 0.3 bar is to be set as the lower signal

pressure range.

The new bench range of 0.3 to 1.1 bar must

be marked on the nameplate as bench

range with pretensioned springs.

2.2 Valve and actuator that have

different rated travels

Actuators with springs that have already

been pretensioned by the manufacturer

without attachment to a valve are marked by

an appropriate label.

In addition, such actuators can be identified

by three bolts and nuts protruding from the

bottom diaphragm case which allow the

compression of the springs to be unloaded

evenly before removing the actuator from

the valve.

EB 8093 EN 7

Assembling and adjusting valve and actuator

3 Installation

3.1 Mounting position

The valve can be mounted in any position.

It must be installed free of tension.

If necessary, supports can be mounted on

the pipelines near the connections.

Caution!

Prior to weld the valve body into the

pipeline, apply the loading pressure for

valves with fail-safe action “Actuator stem

extends” (valve closed), to move the valve

plug out of the seat. This prevents the trim

from being damaged by excessive high

temperatures.

Note:

Remove the stopper from the test connection

(4.4) to allow the metal bellows (6.3) to be

monitored for leakage.

3.2 Signal pressure line

Connect the signal pressure line for valves

with actuator version "Actuator stem ex-

tends" to the loading pressure connection on

the bottom diaphragm case, and for valves

with actuators "Actuator stem retracts" to the

loading pressure connection on the top dia-

phragm case.

The lower connection of Type 3277 Actuator

is located on the yoke of the bottom dia-

phragm case.

4 Operation

To reverse the direction of action, refer to

Mounting and Operating Instructions of the

respective pneumatic actuator.

EB 8310 EN for Type 3271 and

EB 8311 EN for Type 3277.

5 Maintenance

If leakage occurs, this could be caused by a

damaged metal bellows (6.3) or a defective

packing (4.2).

If the valve does not seal properly, the tight

shut-off may be impeded by dirt or other im-

purities caught between the seat and plug,

or by damaged facings.

Remove the parts, clean them thoroughly

and replace them with new ones, if neces-

sary.

Before servicing or disassembling the

control valve, depressurize the con-

cerned section of the plant and drain

it.

Wait until the medium has reached

ambient temperature, if necessary.

As valves are not free of cavities,

there might still be residual medium

in the valve. We recommend remov-

ing the valve from the pipeline or re-

move the entire valve assembly when

the valve is welded in the pipeline.

On performing any work on the

valve body, first shut off the supply

pressure, disconnect the supply pres-

sure line and remove the actuator.

8EB 8093 EN

Installation

Note:

Seat wrenches can be ordered using the

following order numbers:

For DN 15 to 150: Complete set 1280-3047

For DN 15 and 25: Single set 1280-3073

5.1 Replacing packing, seat, and

plug

Removing the actuator

Prior to performing any work on the valve

body, remove the actuator first.

Note!

For actuators with fail-safe action "Actuator

stem extends" and especially actuators with

pretensioned springs, apply a pressure

slightly higher than the lower signal pressure

range (see actuator nameplate) to the

loading pressure connection on the bottom

diaphragm chamber, before loosening the

annular nut (8.2).

1. Remove clamps of the stem connector (7)

between actuator stem and plug stem

and unscrew annular nut (8.2).

2. Lift the actuator off the valve.

Caution!

To avoid damaging the metal bellows, make

sure that no torque is transmitted to the

bellows welded to the plug stem extension

(6.3, 6.3 b).

Packing

1. Place a wrench at the stem connector nut

(6.1) to hold it stationary and loosen the

lock nut (6.2). Unscrew stem connector

nut and lock nut.

2. Unthread guide bushing (5.2) to relieve

the tension from the packing.

3. Unthread the nuts (5.3) at the valve bon-

net. Lift valve bonnet (5) upwards off the

flanged section of the cryogenic exten-

sion bonnet (1.1) .

4. Unthread threaded bushing (5.2) and

use a suitable tool to remove the pack-

ing rings (4.2), washer (4.3), and spring

(4.1).

Replace damaged parts with new ones.

Carefully clean the packing chamber.

EB 8093 EN 9

Maintenance

Fig. 3 · Sectional drawing

Plug:

Caution! Do not twist the bellows!

1. Use SAMSON socket wrench to unscrew

the bellows nut (6.4). Pull plug stem ex-

tension together with the bellows seal,

guide bushing (6.6), and the plug stem

and plug out of the cryogenic extension

bonnet.

2. Used a suitable tool to clamp the cryo-

genic extension bonnet tightly.

3. Unthread the plug out of the extension.

4. Loosen nut (6.7). Unscrew guide bushing

(6.6). In the case of large nominal sizes,

unscrew second nut and remove guide

bushing.

Note! There is no guide bushing (6.6) in

valve sizes NPS 4 and 6/Class 150 - 300,

version with split plug stem extension.

5. Apply lubricant (order no. 8150-0116)

to the plug stem thread of the new or

original plug that has been machined.

6. Screw guide bushing (6.6) onto the plug

stem extension as far as it will go. Lock

into position with the nut (6.7) or slide

on the guide bush and fasten with two

nuts.

7. Check that both washers (6.8) are still in

the plug stem extension. Screw the plug

stem tightly into the plug stem extension.

Tightening torque: 50 Nm with DN 25

to 80 and 80 Nm with DN 100 to 150.

Seat:

If the seat must also be replaced, proceed as

follows:

8. Use a SAMSON seat wrench to unscrew

the seat (2) out of the valve body.

9. Apply lubricant (order no. 8150-0116)

to the seat thread of the new seat and

screw in tightly observing the tightening

torques in Table 1.

Assembly:

1. Slide plug stem extension together with

guide bushing and plug into the body.

2. Insert bellows nut (6.4) and screw tight

(observing tightening torques in the table

below). Make sure that no torque is

transmitted to the bellows.

10 EB 8093 EN

Maintenance

Table 1 Tightening torque Nm or steel and aluminum version

Nominal size Seat (2) Bellows nut

(6.4) Body nut

(5.3)

Body nut (1.3)

only with aluminum

angle valves

DN NPS Red. seat bore Max. seat bore

15 to 25 ½ to 1 150 150 200 30 20

32 to 50 1½ to 2 450 400 1000 60 30

65 to 80 2½ to 3 900 850 2000 100 60

100 4 1400 1050 3000 100 100

150 6 2300 2100 3000 100 100

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