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Summary of Contents for Samson 3595
- Page 1 EB 8079 EN Translation of original instructions Type 3595 Valve with Type 3271 Actuator Type 3595 Valve · ANSI version For combination with actuators, such as Type 3276 or Type 3271 Pneumatic Actuators Edition November 2019...
- Page 2 Note on these mounting and operating instructions These mounting and operating instructions assist 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 may vary.
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Page 3: Table Of Contents
Contents Safety instructions and measures ..............1-1 Notes on possible severe personal injury ............1-4 Notes on possible personal injury ..............1-4 Notes on possible property damage .............1-6 Markings on the device ................2-1 Valve nameplate ..................2-1 Actuator nameplate ..................2-1 Design and principle of operation ...............3-1 Fail-safe positions ..................3-1 Versions .....................3-3 Additional fittings ..................3-4... - Page 4 Removal ....................11-1 11.1 Removing the valve from the pipeline ............11-1 11.2 Removing the actuator from the valve ............11-2 Repairs ....................12-1 12.1 Returning devices to SAMSON ..............12-1 Disposal ....................13-1 Certificates ....................14-1 Annex......................15-1 15.1 Tightening torques, lubricants and tools ............15-1 15.2 Spare parts ....................15-3 15.3...
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Page 5: Safety Instructions And Measures
In case operators intend to use the control valve in other applica- tions or conditions than specified, contact SAMSON. SAMSON does not assume any liability for damage resulting from the failure to use the de- vice for its intended purpose or for damage caused by external forces or any other external factors. - Page 6 (see associated actuator documentation). For example, when the valve is combined with a SAMSON Type 3271 Pneumatic Actuator, the valve moves to a certain fail- safe position (see the 'Design and principle of operation' section) upon supply air or control signal failure.
- Page 7 Safety instructions and measures Hazards resulting from the special working conditions at the installation site of the valve must be identified in a risk assessment and prevented through the corresponding safety instruc- tions drawn up by the operator. Responsibilities of the operator The operator is responsible for proper operation and compliance with the safety regulations.
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Page 8: Notes On Possible Severe Personal Injury
Safety instructions and measures 1.1 Notes on possible severe personal injury DANGER Risk of bursting in pressure equipment. Valves and pipelines are pressure equipment. Impermissible pressure or improper opening can lead to valve components bursting. Î Observe the maximum permissible pressure for valve and plant. Î... - Page 9 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.
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Page 10: Notes On Possible Property Damage
Risk of valve damage due to the use of unsuitable tools. Certain tools are required to work on the valve. Î Only use tools approved by SAMSON (see the 'Tightening torques, lubricants and tools' section in the annex of these instructions). - Page 11 The lubricants to be used depend on the valve material. Unsuitable lubricants may cor- rode and damage the surface. Î Only use lubricants approved by SAMSON (see the 'Tightening torques, lubricants and tools' section in the annex of these instructions).
- Page 12 EB 8079 EN...
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Page 13: Markings On The Device
Markings on the device 2 Markings on the device 2.1 Valve nameplate The valve nameplate describes the key char- acteristics of the valve, such as: − Type designation − Valve size − Pressure rating − Date of manufacture − Serial number It is located on the valve body. - Page 14 Markings on the device The location of the valve nameplate varies depending on the valve size: − Valve body − Yoke EB 8079 EN...
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Page 15: Design And Principle Of Operation
The valve has a clamped-in seat. The seat is Valve style and actuator inserted into the seat bridge. The seat and The Type 3595 Valve is a cage valve de- cage are clamped into place by tightening signed as globe or angle valve. The valve the body nuts. - Page 16 Design and principle of operation Fig. 3-1: Type 3595 Valve with Type 3271 Actuator EB 8079 EN...
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Page 17: Versions
In these instructions, the preferable combina- valve. The valve closes when the signal tion with a SAMSON Type 3276 or pressure is increased enough to over- Type 3271 Pneumatic Actuator is described. come the force exerted by the springs. -
Page 18: Additional Fittings
Noise emissions stream of the valve and installing a bypass line. The bypass line ensures that the plant SAMSON is unable to make general state- does not need to be shut down for service ments about noise emissions. The noise emis- and repair work on the valve. - Page 19 Design and principle of operation Table 3-1: Technical data Type 3595 Globe Valve Cast body Forged body Valve size NPS ¾ to 2 NPS 3 to 32 NPS ¾ to 2 NPS 3 to 12 Pressure rating Class 150 to 2500 Flanges • • •...
- Page 20 Design and principle of operation Table 3-3: Dimensions of Type 3595 Valve · Valve body with welding ends or welding-neck ends Table 3-3.1: NPS ¾ to 4 · Dimensions in inches and mm Valve size NPS Dimension Pressure rating ¾ 1½ 7.36 7.36 8.74...
- Page 21 Design and principle of operation Table 3-3.2: NPS 6 to 16 · Dimensions in inches and mm Valve size NPS Dimension Pressure rating 21.38 29.61 32.24 33.5 43.62 Class 150 to 600 1108 20.00 24.02 30.00 35.98 49.49 55.98 Class 900 Length L and 1500 1257 1422 24.02...
- Page 22 Design and principle of operation Table 3-4: Dimensions of Type 3595 Valve · Flanged valve body version Table 3-4.1: NPS ¾ to 4 · Dimensions in inches and mm Valve size NPS ¾ 1½ Flange form Dimension Pressure rating 7.24 – 7.24 –...
- Page 23 Design and principle of operation Table 3-4.2: NPS 6 to 16 · Dimensions in inches and mm Valve size NPS Flange form Dimension Pressure rating 17.76 – 21.38 – 26.50 – 29.02 – 35.00 – 40.00 – Class 150 – – – – –...
- Page 24 2500 mm On request On request On request On request On request On request H3 with Type 3271 Actuator, see Table 3-7 Only with Type 3271 Actuator Table 3-5: Type 3595 Valve without actuator · Weights in kg Valve size (NPS) Pressure rating Weight ¾...
- Page 25 Design and principle of operation Table 3-6: Dimensions for Type 3276 Pneumatic Actuator Version (effective diaphragm area) Dimension 330 (387 cm²) 350 (645 cm²) 380 (1032 cm²) 390 (1032 cm²) 17.09 27.17 27.91 34.02 Stem extends Height 17.6 27.76 31.85 36.65 Stem retracts 11.50 15.12 17.99 17.99 ØD...
- Page 26 Design and principle of operation Dimensional drawings ØD ØD ØD1 Type 3595 Globe Valve with Type 3276 Type 3595 Globe Valve with Type 3271 Pneumatic Actuator · Body with welding Pneumatic Actuator · Flanged body ends or welding-neck ends 3-12 EB 8079 EN...
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Page 27: Shipment And On-Site Transport
2. Check the shipment for transportation Î Stay clear of suspended or moving damage. Report any damage to loads. SAMSON and the forwarding agent (re- Î Close off and secure the transport paths. fer to delivery note). 3. Determine the weight and dimensions of... -
Page 28: Transporting The Valve
Transport instructions A swivel hoist can be screwed into − Protect the control valve against external SAMSON actuators with a female thread on influences (e.g. impact). the top diaphragm case in place of the eye- − Do not damage the corrosion protection bolt (see associated actuator documenta- (paint, surface coatings). - Page 29 Shipment and on-site transport − The permissible transportation tempera- ture of standard control valves is –20 to +65 °C/–4 to +149 °F. Note Contact our after-sales service for the trans- portation temperatures of other valve ver- sions. Fig. 4-1: Lifting points on the control valve: with flanges (left) and with welding ends or welding-neck ends (right) EB 8079 EN...
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Page 30: Lifting The Valve
2. Version with welding ends or weld- Class 900 and higher as well as ≥NPS 24. ing-neck ends: secure the slings (or other Î Contact SAMSON's After-sales Service. suitable lifting tackle) attached to the valve body against slipping using a con- To install a large valve into the pipeline, use nector. -
Page 31: Storage
Î Observe the storage instructions. other valve versions. Î Avoid long storage times. − Do not place any objects on the control Î Contact SAMSON in case of different valve. storage conditions or long storage peri- ods. Special storage instructions for elastomers Elastomer, e.g. - Page 32 EB 8079 EN...
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Page 33: Installation
–10 °C (14 °F) Plant operators must ensure that, after instal- lation of the device, the operating personnel Î Contact SAMSON if the mounting posi- can perform all necessary work safely and tion is not as specified above. easily access the device from the work posi- Support or suspension tion. - Page 34 Fig. 5-1. avoid excess pressure in the device). Further- more, the vent plugs allow air intake to pre- Î Contact SAMSON's After-sales Service vent a vacuum from forming in the device. for additional points of attachment. Î Locate the vent plug on the opposite side to the work position of operating person- nel.
- Page 35 Installation Table 5-1: Inlet and outlet lengths Flow rate Inlet length Outlet length a x NPS b x NPS State of Inlet length Outlet length process Valve conditions 1) 2) medium Ma ≤ 0.3 0.3 ≤ Ma ≤ 0.7 Ma ≤ 0.3 3) Vapor 0.3 ≤ Ma ≤ 0.7 3) Saturated steam (percentage of condensate > 5 %) Free of cavitation/w < 10 m/s Cavitation producing noise/w ≤ 3 m/s Liquid...
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Page 36: Preparation For Installation
Risk of valve damage due to the use of un- Î Flush the pipelines. suitable tools. Î Only use tools approved by SAMSON (see the 'Tightening torques, lubricants Note and tools' section in the annex). The plant operator is responsible for clean- ing the pipelines in the plant. -
Page 37: Mounting The Actuator Onto The Valve
(see associated actuator row on the valve indicates the direction documentation). of flow. Depending on the version, SAMSON control 5. Make sure that the correct flange gaskets valves are either delivered with the actuator are used. already mounted on the valve or the valve 6. -
Page 38: Testing The Installed Valve
Installation 5.4 Testing the installed valve cessories not fitted with noise-reducing fit- tings. Both can damage hearing. Î Wear hearing protection when working DANGER near the valve. Risk of bursting due to incorrect opening of pressurized equipment or components. Valves and pipelines are pressure equipment WARNING WARNING that may burst when handled incorrectly. -
Page 39: Leak Test
Installation 5. Check the valve for leakage to the atmo- WARNING sphere. Risk of personal injury due to preloaded 6. Depressurize the pipeline section and springs. valve. Actuators with preloaded springs are under 7. Rework any parts that leak (see informa- tension. -
Page 40: Fail-Safe Position
Installation Î Apply the maximum and minimum con- trol signals to check the end positions of the valve. Î Check the travel reading at the travel in- dicator scale. 5.4.3 Fail-safe position Î Shut off the signal pressure line. Î Check whether the valve moves to the fail-safe position (see the 'Design and principle of operation' section). -
Page 41: Start-Up
Start-up 6 Start-up Î Wear hearing protection when working near the valve. The work described in this section is only to be performed by personnel qualified for the assignment accordingly. WARNING WARNING Crush hazard arising from actuator and WARNING plug stem moving. Risk of burn injuries due to hot or cold com- Î... - Page 42 Start-up Before start-up or putting the valve back into service, make sure the following conditions are met: − The valve is properly installed into the pipeline (see the 'Installation' section). − The leak and function tests have been completed successfully (see the 'Testing the installed valve' section).
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Page 43: Operation
Operation 7 Operation WARNING WARNING Immediately after completing start-up or put- Crush hazard arising from actuator and ting the valve back into operation (see the plug stem moving. 'Start-up' section), the valve is ready for use. Î Do not insert hands or finger into the yoke while the air supply is connected to the actuator. -
Page 44: Working In Manual Mode
Operation 7.2 Working in manual mode Valves with actuators with a handwheel can be manually closed or opened in case of supply air failure. 7.3 Lubricator for the packing chamber In some applications, a lubricator for the packing chamber is required. This lubricator is fitted with a check valve to prevent return flow into the process medium. -
Page 45: Malfunctions
Malfunctions 8 Malfunctions 8.1 Troubleshooting Malfunction Possible reasons Recommended action Actuator and plug stem Actuator is blocked. Check attachment. do not move on Unblock the actuator. demand. WARNING! A blocked actuator or plug stem (e.g. due to seizing up after remaining in the same position for a long time) can suddenly start to move uncontrollably. - Page 46 Malfunctions Malfunction Possible reasons Recommended action Increased flow through Dirt or other foreign Shut off the section of the pipeline and flush the closed valve (seat particles deposited valve. leakage) between the seat and plug. Faces on the seat ring See 'Lapping the seat and plug' in the 'Servicing' and plug are slightly section.
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Page 47: Emergency Action
Malfunctions 8.2 Emergency action The plant operator is responsible for emer- gency 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. - Page 48 EB 8079 EN...
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Page 49: Servicing
Servicing 9 Servicing Î Allow components and pipelines to cool down or heat up. The work described in this section is only to Î Wear protective clothing and safety be performed by personnel qualified for the gloves. assignment accordingly. The following documents are also necessary WARNING for servicing the valve: Risk of personal injury due to pressurized... - Page 50 Risk of valve damage due to the use of un- WARNING suitable tools. Risk of personal injury due to preloaded Î Only use tools approved by SAMSON springs. (see the 'Tightening torques, lubricants Actuators with preloaded springs are under and tools' section in the annex).
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Page 51: Periodic Testing
1. Lay out the necessary material and tools Note to have them ready for the service work. The control valve was checked by SAMSON 2. Put the control valve out of operation (see before it left the factory. the 'Decommissioning' section). -
Page 52: Mounting The Valve After Service Work
Servicing 9.3 Mounting the valve after torque over several rounds. Observe the specified tightening torques and se- service work quence (see the 'Tightening torques, lu- 1. Place the seat ring with the gasket into bricants and tools' section in the annex). the valve body. -
Page 53: Replacing The Packing
Servicing Gasket U-ring Fig. 9-2: Aligning the U-ring Gasket 9.4.2 Replacing the packing 1. Unthread the nuts of the packing gland Fig. 9-1: Arrangement of gaskets from the valve bonnet. 2. Remove the packing gland and packing follower. NOTICE 3. Pull the plug stem together with the plug Insufficient seal performance due to incor- downwards out of the valve bonnet. -
Page 54: Replacing The Bellows Seal
Servicing 5. Clean the packing chamber thoroughly. Double packing Single packing 6. Renew damaged parts. 7. Apply a suitable lubricant to all the pack- Packing ing parts and to the plug stem (see the gland 'Tightening torques, lubricants and tools' Stud Packing section in the annex). -
Page 55: Lapping The Seat And Plug
Servicing ing a suitable tool. Make sure to observe Î Contact SAMSON's After-sales Service the proper order (see Fig. 9-3). department when reworking is required. 7. Carefully slide the packing follower Necessary conditions for lapping downwards over the plug stem. In addition to preparation before performing 8. - Page 56 Servicing plug. This leads to a changed flow rate and plug stem and press the plug by hand in- changes the control characteristics of the to the seat. Apply compressed air to the valve as a result. inlet side of the valve. Repeat the lapping Î...
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Page 57: Ordering Spare Parts And Operating Supplies
Servicing 9.5 Ordering spare parts and operating supplies Contact your 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 Annex for details on suitable lubricants. - Page 58 9-10 EB 8079 EN...
- Page 59 EB 8079 EN 9-11...
- Page 60 9-12 EB 8079 EN...
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Page 61: Decommissioning
Decommissioning 10 Decommissioning WARNING The work described in this section is only to Risk of personal injury due to pressurized be performed by personnel qualified for the components and process medium escaping assignment accordingly. under pressure. Î Do not loosen the screw of the test con- nection while the valve is pressurized. - Page 62 Decommissioning (e.g. due to seizing up after remaining in 3. Disconnect and lock the pneumatic air the same position for a long time), re- supply to depressurize the actuator. lease any stored energy in the actuator 4. If necessary, allow the pipeline and valve (e.g.
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Page 63: Removal
Removal 11 Removal WARNING WARNING The work described in this section is only to Risk of personal injury due to residual pro- be performed by personnel qualified for the cess medium in the valve. assignment accordingly. While working on the valve, residual process medium can escape and, depending on its properties, may lead to personal injury, e.g. -
Page 64: Removing The Actuator From The Valve
Removal 2. Unbolt the flange joint. 3. Remove the valve from the pipeline (see the 'Shipment and on-site transport' sec- tion). b) Version with welding ends 1. Support the valve to hold it in place when separated from the pipeline (see the 'Shipment and on-site transport' sec- tion). -
Page 65: Repairs
Î Do not perform any repair work on your outside of your shipment so that the own. documents are clearly visible. Î Contact SAMSON's After-sales Service 4. Send the shipment to the address given for repair work. on the RMA. - Page 66 12-2 EB 8079 EN...
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Page 67: Disposal
Disposal 13 Disposal Î Observe local, national and internation- al refuse regulations. Î Do not dispose of components, lubricants and hazardous substances together with your household waste. EB 8079 EN 13-1... - Page 68 13-2 EB 8079 EN...
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Page 69: Certificates
Certificates 14 Certificates The declaration of conformity in accordance with Pressure Equipment Directive 2014/68/ EU is provided on the next page: EB 8079 EN 14-1... - Page 70 14-2 EB 8079 EN...
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Page 71: Annex
Annex 15 Annex 15.1 Tightening torques, lubricants and tools Tightening torques Table 15-1: Tightening torques for nuts on the valve bonnet/body and tightening sequence Valve Increase in tight- Required tightening size Thread pitches ening torque torque Tightening sequence per inch ft·lb ft·lb ½... - Page 72 Annex Lubricants Table 15-3: Lubricant and lapping compound Parts/ Clean- Lubricant pairs of parts Reason Application 1) Inside and Before long periods of outside of the storage to protect the valve Apply a thin film valve against corrosion To make the plug move Machine oil Plug stem easier during lapping of...
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Page 73: Spare Parts
You can reach our after-sales service at aftersalesservice@samsongroup.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 our website (www.samsongroup.com) or in all SAMSON product catalogs. - Page 74 15-4 EB 8079 EN...
- Page 76 EB 8079 EN SAMSON AKTIENGESELLSCHAFT Weismüllerstraße 3 · 60314 Frankfurt am Main, Germany Phone: +49 69 4009-0 · Fax: +49 69 4009-1507 samson@samsongroup.com · www.samsongroup.com...
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