Samson 3525 Mounting And Operating Instructions
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Samson 3525 Mounting And Operating Instructions

Samson 3525 Mounting And Operating Instructions

Globe valve in combination with an actuator such as samson type 3571 pneumatic actuator
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Type 3525 Globe Valve
In combination with an actuator
such as SAMSON Type 3571 Pneumatic Actuator
ANSI version
Mounting and
Operating Instructions
EB 8823 EN
Edition March 2017

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  • Page 1 Type 3525 Globe Valve In combination with an actuator such as SAMSON Type 3571 Pneumatic Actuator ANSI version Mounting and Operating Instructions EB 8823 EN Edition March 2017...
  • Page 2 The instructions are binding for handling SAMSON devices. Î For the safe and proper use of these instructions, read them carefully and keep them for future reference. Î If you have any questions about these instructions, contact SAMSON‘s After-sales Service Department (samson@samsongroupna.com). Referenced documentation The following documents apply in addition to these mounting and operating instructions: −...

  • Page 3: Table Of Contents

    Contents Safety instructions and safety measures ............5 Notes on possible severe personal injury ............7 Notes on possible personal injury ..............7 Notes on possible property damage ..............9 Markings on the control valve ..............10 Valve nameplate ..................10 Actuator nameplate ..................11 Material number ..................11 Design and principle of operation ..............12 Fail-safe positions ..................14 Technical data .....................15...
  • Page 4 Contents Compact version ..................40 7.2.1 Replacing the O-rings ..................40 7.2.2 Replacing the packing ..................40 7.2.3 Replacing the seat and plug ................42 7.2.4 Tools and tightening torques................44 Preparation for return shipment ..............44 Ordering spare parts and operating supplies ..........45 Malfunctions ....................46 Troubleshooting ...................46 Emergency action ..................47 Decommissioning and disassembly ..............48...

  • Page 5: Safety Instructions And Safety Measures

    In case operators intend to use the control valve in other applications or conditions than specified, SAMSON must be contacted. SAMSON does not assume any liability for damage resulting from the failure to use the valve for its intended purpose or for damage caused by external forces or any other external factors.
  • Page 6 Î Check with the plant operator for details on further protective equipment. Revisions and other modifications Revisions, conversions or other modifications to the product are not authorized by SAMSON. They are performed at the user‘s own risk and may lead to safety hazards. Furthermore, the control valve may no longer meet the requirements for its intended use.

  • Page 7: Notes On Possible Severe Personal Injury

    Safety instructions and safety measures Referenced standards and regulations The SAMSON Type 3525 Globe Valve complies with the requirements of ASME B16.34. 1.1 Notes on possible severe personal injury DANGER Risk of bursting in pressure equipment. Control valves and pipelines are pressure equipment. Improper opening can lead to valve components bursting.
  • Page 8 Risk of personal injury due to preloaded springs. Valves in combination with pneumatic actuators with preloaded springs are under ten- sion. These control valves with SAMSON pneumatic actuators can be identified by the long bolts protruding from the bottom of the actuator.

  • Page 9: Notes On Possible Property Damage

    Risk of valve damage due to the use of unsuitable lubricants. The lubricants to be used depend on the valve material. Unsuitable lubricants may cor- rode and damage the valve surface. Î Only use lubricants approved by SAMSON (see parts list). EB 8823 EN...

  • Page 10: Markings On The Control Valve

    Stellite ® ® TC: tungsten carbide Option code for trim identification (stem, plug, seat) For Intermediate Rating Standard Class: pressure and upper temperature limit For other pressure ratings: upper temperature limit Not used Fig. 1: Type 3525 nameplate EB 8823 EN...

  • Page 11: Actuator Nameplate

    Markings on the control valve 2.3 Material number The valve nameplate is affixed to the rear of the body. The seat and plug of the valves have an arti- cle number written on them. Specifying this article number, you can contact us to find out which material is used.

  • Page 12: Design And Principle Of Operation

    There are three versions available: ation − Standard globe valve with flanges (see Fig. 3) or threaded ends The single-seated Type 3525 Globe Valve is − Compact globe valve with threaded ends combined with a SAMSON Type 3571 − Compact T-pattern valve with threaded Pneumatic Actuator (see Fig. 4).
  • Page 13 Design and principle of operation Fig. 3: Standard version Type 3525 Globe Valve with Type 3571 Pneumatic Actuator Safety bleed Plug stem Body Yoke assembly with Bonnet travel indicator Seat (82, 83, 84) Plug (29, 36) Screw Guide bushing Hanger Spring Travel indicator scale Fig. 4: Bonnet for standard...

  • Page 14: Fail-Safe Positions

    127 Seat ring gasket Actuator stem A16 Vent plug A28 Stem connector clamp Signal pressure connection Fig. 5: Compact version Type 3525 T-pattern Valve with Type 3571 Pneumatic Actuator 3.1 Fail-safe positions creased enough to overcome the force exert- ed by the springs.

  • Page 15: Technical Data

    More information is available in Data Sheet Table 1 and Table 2 provide a summary of u T 8823. the dimensions and weights of the standard and compact version of Type 3525 Valve. Temperature range The lengths and heights are shown in the di- mensional drawings on p. 16 (standard The valve version with an HNBR O-ring is version) and p. 17 (compact version).
  • Page 16 Design and principle of operation Table 1: Dimensions of Type 3525 Valve · standard version Body Version Standard globe valve type Connection 8.27 8.27 – 11.26 11.38 9.06 13.27 13.39 Class 600 – 10.75 10.75 6.26 13.39 13.50 9.06 15.24 15.35 Class 900 10.75 10.75...
  • Page 17 Design and principle of operation Table 2: Dimensions of Type 3525 Valve · compact versions Body Compact Compact Version type globe valve T-pattern valve Connection Class 600 – – 4.69 4.69  1) Class 900  1) Class 1500 – – Class 1700 6.18 6.18 1.69 2.36  1)  1)
  • Page 18 Design and principle of operation Table 3: Weights for Type 3525 Valve Compact Body type Compact Version T-pattern Standard globe valve globe valve valve – – 34.4 60.6 83.8 RF/RTJ – – 15.6 27.5 Class 600 – – – 44.1 – – –...
  • Page 19 EB 8823 EN...

  • Page 20: Preparation

    2. Check the shipment for transportation WARNING damage. Report any damage to Risk of lifting equipment tipping and risk of SAMSON and the forwarding agent (re- damage to lifting accessories due to exceed- fer to delivery note). ing the rated lifting capacity.

  • Page 21: Transporting

    The control valve can be transported using tached slings. lifting equipment (e.g. crane or forklift). The welded-on lifting eyelet on SAMSON Î Leave the control valve in its transport actuators (116 in²/750 cm²) is only intended container or on the pallet to transport it.
  • Page 22 Preparation − Prevent the control valve from tilting or tilting while being lifted. Before lifting the tipping. control valve, tighten the sling. − Do not leave loads suspended when in- Version with flanges or threaded ends terrupting work for longer periods of 1.

  • Page 23: Storage

    − Do not place any objects on the control Risk of valve damage due to improper stor- valve. age. − Observe storage instructions. − Avoid long storage times. − Contact SAMSON in case of different stor- age conditions or longer storage times. EB 8823 EN...

  • Page 24: Preparation For Installation

    Components may − Store soft parts away from lubricants, loosen during transport. chemicals, solutions and fuels. SAMSON’s After-sales Service department can provide more detailed storage instruc- tions on request. 4.4 Preparation for installation Proceed as follows: Î...
  • Page 25 EB 8823 EN...

  • Page 26: Mounting And Start-Up

    Mounting and start-up 5 Mounting and start-up 5.2 Installing the valve into the pipeline SAMSON valves are delivered ready for use. In special cases, the valve and actuator 5.2.1 Checking the installation are delivered separately and must be assem- bled on site. The procedure to mount and...
  • Page 27 Mounting and start-up Table 4: Inlet and outlet lengths Flow rate Inlet length Outlet length a x NPS b x NPS State of process Valve conditions Inlet length a Outlet length b medium Ma ≤ 0.3 0.3 ≤ Ma ≤ 0.7 Ma ≤ 0.3  1) 0.3 ≤ Ma ≤ 0.7  1) Vapor Saturated steam (percentage of con- densate > 5 %) Free of cavitation/w < 33 ft/s (w < 10 m/s)

  • Page 28: Additional Fittings

    Attach a suitable support or suspension on Note the valve, if necessary. Contact SAMSON’s After-sales Service de- partment in case that an insulation is re- Vent plugs quired. Vent plugs are screwed into the exhaust air ports of pneumatic, electropneumatic and 5.2.3...

  • Page 29: Quick Check

    5.3 Quick check lowing conditions are met: − Retract the plug to open the valve. SAMSON valves are delivered ready for − Observe the maximum permissible pres- use. To test the valve’s ability to function, the sure for both the valve and plant.

  • Page 30: Operation

    WARNING To reverse the flow direction, contact Risk of personal injury due to sudden escape SAMSON’s After-sales Service department. of process medium. The valve has a safety bleed to detect dam- aged or worn O-rings. The process medium may escape suddenly and at high pressure.
  • Page 31 EB 8823 EN...

  • Page 32: Maintenance

    − Wear protective clothing, gloves and eye- wear when working near or on the valve. − Do not stay in the range of the safety bleed SAMSON’s After-sales Service department longer than necessary. can support you to draw up a maintenance plan for your plant.

  • Page 33: Standard Version

    2. Apply a signal pressure to the actuator to Note slightly lift the plug off the seat. Unscrew The control valve was checked by SAMSON the bonnet (2). before it left the factory. 3. Lift bonnet (2) and plug with plug stem −...
  • Page 34 Maintenance Fig. 7: Standard version Type 3525 Globe Valve with Type 3571 Pneumatic Actuator Body Plug head Bonnet Plug stem Seat Yoke assembly with travel indicator (82, 83, 84) Plug (29, 36) Screw Guide bushing Hanger Spring Travel indicator scale Washer Seat ring gasket...
  • Page 35 Maintenance 5. Apply a suitable lubricant to the new 8. Place bonnet (2) with plug and plug stem O-rings (17). Insert O-rings into the bon- (5) onto the body (1). Tighten by hand. net (2). Make sure that the O-rings rest 9.

  • Page 36: Replacing The Packing

    Maintenance End position Flap of tab washer Bent flap Fig. 9: Mounting the bonnet onto the body 7.1.2 Replacing the packing Note It is not necessary to completely remove the NOTICE actuator from the valve to replace the pack- Risk of valve damage due to abrasion. ing.
  • Page 37 Maintenance 16. Screw bonnet (2) with plug and plug NOTICE stem (5) into the body (1). Observe tight- Risk of leakage due to damaged packing ening torques. chamber, packing parts and plug stem. 17. Bend up the flap of the tab washer (224) When inserting the assembly into the bonnet so that it rests against the bonnet.

  • Page 38: Replacing The Seat And Plug

    Maintenance 7.1.3 Replacing the seat and 4. Replace O-rings (17) as described in section 7.1.1. plug 5. Unscrew the seat (4) using a suitable tool. NOTICE 6. Remove seat ring gasket (127) from the Risk of damage to the facing of the seat and body (1) and carefully clean the sealing plug due to abrasion and incorrect service face.

  • Page 39: Tools And Tightening Torques

    Maintenance 18. Screw bonnet (2) with plug and plug stem (5) into the body (1). Observe tight- ening torques. 19. Bend up the flap of the tab washer (224) so that it rests against the bonnet. Note For detailed information on mounting the tab washer and bonnet see section 7.1.1, steps 7 to 10.

  • Page 40: Compact Version

    Maintenance 7.2 Compact version 7.2.2 Replacing the packing 7.2.1 Replacing the O-rings NOTICE Risk of valve damage due to abrasion. The plug and seat facings are very sensitive. NOTICE Before unscrewing the bonnet from the body, Risk of valve damage due to abrasion. apply a signal pressure to the actuator to The plug and seat facings are very sensitive.
  • Page 41 Maintenance Fig. 11: Compact version Type 3525 T-pattern Valve with Type 3571 Pneumatic Actuator 36 5 Fig. 12: Packing Body O-ring Bonnet Plug head Yoke Plug stem Seat Lock nut Plug (29, 36) Screw plug Guide bushing Seat ring gasket Spring Actuator stem Washer...

  • Page 42: Replacing The Seat And Plug

    Maintenance 7.2.3 Replacing the seat and 9. Slide guide bushing (7) and packing parts over the plug stem. Make sure you plug observe the proper order (see Fig. 12). 10. Carefully insert plug with plug stem, NOTICE packing parts and guide bushing into the Risk of damage to the facing of the seat and bonnet.
  • Page 43 Maintenance Tungsten carbide or ceramic plug 4. Unscrew the seat (4) using a suitable tool. 1. Remove stem connector clamp (A28). 5. Remove seat ring gasket (127) from the See associated actuator documentation. body (1) and carefully clean the sealing face.

  • Page 44: Tools And Tightening Torques

    > Services > Check- lists for after-sales service > Declaration on Contamination. 4. Send the valve together with the filled-in form to your nearest SAMSON subsidi- ary. SAMSON subsidiaries are listed on our website at u www.samsoncontrols.com > Contact. Table 6: Tools and tightening torques for compact version...

  • Page 45: Ordering Spare Parts And Operating Supplies

    Spare Parts See section 10.3 for details on spare parts. Lubricants Details on suitable lubricants can be found in the parts list. Note For further information contact your nearest SAMSON subsidiary or the SAMSON After- sales Service department. EB 8823 EN...

  • Page 46: Malfunctions

    Depending on the operating conditions, check the valve at certain intervals to prevent possi- ble failure before it can occur. Operators are responsible for drawing up a test plan. SAMSON’s After-sales Service department can support you to draw up an inspection plan for your plant.

  • Page 47: Emergency Action

    7.2.3) or contact SAMSON's After-sales Service department. Note Contact SAMSON’s After-sales Service department for malfunctions not listed in the table. 8.2 Emergency action Upon supply air or control signal failure, the valve moves to its fail-safe position (see sec- tion 3.1).

  • Page 48: Decommissioning And Disassembly

    Decommissioning and disassembly 9 Decommissioning and Wear protective clothing, gloves and eye- wear. disassembly DANGER WARNING Risk of bursting in pressure equipment. Risk of burn injuries due to hot or cold com- Control valves and pipelines are pressure ponents and pipeline. equipment.

  • Page 49: Removing The Actuator From The Valve

    Decommissioning and disassembly Version with threaded ends 1. Put the control valve out of operation (see section 9.1). 2. Unscrew the valve from the pipeline. 3. Remove the valve from the pipeline (see section 4.2). 9.3 Removing the actuator from the valve See associated actuator documentation.

  • Page 50: Appendix

    You can reach the After-sales Service depart- ment at samson@samsongroupna.com. Addresses of SAMSON AG and its subsid- iaries The addresses of SAMSON AG, its subsid- iaries, representatives and service facilities worldwide can be found on the SAMSON website, in all SAMSON product catalogs or on the back of these Mounting and Operat- ing Instructions.
  • Page 51 EB 8823 EN...

  • Page 52: Spare Parts

    Appendix 10.3 Spare parts Standard version Type 3525 Globe Valve Body Bonnet Seat Plug (29, 36) Guide bushing Spring Washer Packing (11, 12, 16) V-ring packing O-ring Plug head Plug stem Yoke assembly with travel indicator (82, 83, 84) Screw Hanger...
  • Page 53 Appendix Standard version Type 3525 Globe Valve EB 8823 EN...
  • Page 54 Appendix Compact version Type 3525 Globe Valve and T-pattern Valve Body Bonnet Yoke Seat Plug (29, 36) Guide bushing Spring Washer Packing (11, 12, 16) V-ring packing O-ring Plug head Plug stem Yoke assembly with travel indicator (82, 83, 84) Screw...
  • Page 55 Appendix Compact version Type 3525 Globe Valve and T-pattern Valve EB 8823 EN...
  • Page 56 SAMSON CONTROLS INC. 4111 Cedar Boulevard · Baytown, Texas 77523-8588 Phone: +1 281 383-3677 · Fax: +1 281 383-3690 EB 8823 EN samson@samsongroupna.com · www.samsoncontrols.com...

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