Samson 3253 Translation Of Original Instructions
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Samson 3253 Translation Of Original Instructions

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EB 8055 EN
Translation of original instructions
Type 3253 Valve · DIN version
In combination with an actuator,
e.g. a Type 3271 or Type 3277 Pneumatic Actuator
Edition January 2021

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  • Page 1 EB 8055 EN Translation of original instructions Type 3253 Valve · DIN version In combination with an actuator, e.g. a Type 3271 or Type 3277 Pneumatic Actuator Edition January 2021...
  • 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.

  • 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 ..............1-5 Notes on possible property damage .............1-6 Notes on the use of an RFID tag ..............1-7 Warnings on the device ................1-8 Markings on the device ................2-1 Valve nameplate ..................2-1 Actuator nameplate ..................2-2 Material identification number ..............2-2...
  • Page 4 Removal ....................11-1 11.1 Removing the valve from the pipeline ............11-2 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 ....................15-1 15.3...

  • Page 5: Safety Instructions And Measures

    In case operators intend to use the control valve in other applications 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). When the valve is combined with a SAMSON Type 3271 or Type 3277 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 Start-up and shutdown procedures fall within the scope of the operator's duties and, as such, are not part of these mounting and operating instructions. SAMSON is unable to make any statements about these procedures since the operative details (e.g. differential pressures and temperatures) vary in each individual case and are only known to the operator.

  • Page 8: Notes On Possible Severe Personal Injury

    − u AB 0100 for tools, tightening torques and lubricant − Manual u H 02: Appropriate Machinery Components for SAMSON Pneumatic Control Valves with a Declaration of Conformity of Final Machinery − When a substance is used in the device, which is listed as being a substance of very high...

  • Page 9: Notes On Possible Personal Injury

    Safety instructions and measures 1.2 Notes on possible personal injury WARNING Risk of burn injuries due to hot or cold components and pipelines. Depending on the process medium, valve components and pipelines may get very hot or cold and cause burn injuries. Î...

  • Page 10: Notes On Possible Property Damage

    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 11: Notes On The Use Of An Rfid Tag

    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 (u AB 0100). 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 surfaces.

  • Page 12: Warnings On The Device

    Safety instructions and measures 1.5 Warnings on the device Warning Meaning of the warning Location on the device Warning against moving parts There is a risk of injury to hands or fingers through the stroking movement of the actuator and plug stem if they are inserted into the yoke while the air supply is con- nected to the actuator.

  • Page 13: Markings On The Device

    Fig. 2-1 and the inscription table list all pos- 2.1 Valve nameplate sible characteristics and options that may appear on a valve nameplate. Only the in- scriptions relevant to the ordered Type 3253 Valve actually appear on the nameplate. Fig. 2-1: Inscriptions on the valve nameplate Item Inscription meaning...

  • Page 14: Actuator Nameplate

    Markings on the device The valve nameplate (80) is affixed to the bonnet (see Fig. 2-2). Fig. 2-3: Label when an adjustable packing is installed 2.5 Optional RFID tag The RFID tag is located directly next to the nameplate on valves ordered with the RFID tag option.

  • Page 15: Design And Principle Of Operation

    The springs are compressed. Depending on The Type 3253 is a three-way valve which the selected direction of action, the actuator can be used either as a mixing or diverting stem retracts or extends. As a result, the plug valve.
  • Page 16 Design and principle of operation Fig. 3-2: Type 3253 Valve (as diverting valve) Fig. 3-1: Type 3253 Valve (as mixing valve) with Type 3271 Pneumatic Actuator A26/27 EB 8055 EN...

  • Page 17: Versions

    It prevents dard valve version. solid particles in the process medium from damaging the valve. Actuators In these instructions, the preferable combina- tion with a SAMSON Type 3271 or EB 8055 EN...

  • Page 18: Accessories

    Noise emissions Refer to the instructions in the 'Installation' section. SAMSON is unable to make general state- ments about noise emissions. The noise emis- Test connection sions depend on the valve version, plant fa- Versions with bellows seal fitted with a test cilities and process medium.
  • Page 19 Design and principle of operation Table 3-1: Technical data Cast iron Cast steel Cast steel Cast stainless steel Material EN-GJL-250 1.0619 1.7357 1.4408 15 to 15 to 15 to 250 to 150 to 150 to Valve size 150…200 16 to 16 to 16 to 16 to...
  • Page 20 Dimensions and weights Table 3-2 to Table 3-4 provide an overview of the dimensions and weights of the standard version of Type 3253 Valve. The lengths and heights in the dimensional drawings are shown on page 3-7. Dimensions in mm · Weights in kg Table 3-2: Dimensions of Type 3253 Three-way Valve ·...
  • Page 21 PN 400 On request DN 400, up to PN 63 DN 500, up to PN 40 H8 = 650 mm with 250 mm seat bore Table 3-4: Weights for Type 3253 Three-way Valve Valve 100 150 200 250 300 400 500 Valve without PN 10 to 400...
  • Page 22 EB 8055 EN...

  • Page 23: 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 Î Close off and secure the transport paths. (refer to delivery note). 3. Determine the weight and dimensions of...

  • Page 24: Transporting The Valve

    Risk of personal injury due to the control A swivel hoist can be screwed into valve tipping over. SAMSON actuators with a female thread on Î Observe the valve's center of gravity. the top diaphragm case in place of the Î...

  • Page 25: Lifting The Valve

    Shipment and on-site transport 4.3.2 Lifting the valve − Protect the piping and any mounted valve accessories against damage. To install a large valve into the pipeline, use − Protect the control valve against moisture lifting equipment (e.g. crane or forklift) to lift and dirt.

  • Page 26: Storing The Valve

    Elastomer, e.g. actuator diaphragm Î Avoid long storage times. − To keep elastomers in shape and to pre- Î Contact SAMSON in case of different vent cracking, do not bend them or hang storage conditions or long storage peri- them up.
  • Page 27 Shipment and on-site transport EB 8055 EN...
  • Page 28 EB 8055 EN...

  • Page 29: Installation

    The work position for the control valve is the temperatures below –10 °C front view looking onto the operating con- Î Contact SAMSON if the mounting posi- trols (including valve accessories). tion is not as specified above. Plant operators must ensure that, after instal-...
  • Page 30 Installation Mixing service Diverting service Temperature control Q = constant Flow control Q = 0 to 100 % Fail-safe action: FA = "Actuator stem extends", FE = "Actuator stem retracts" In heating applications with FA, the heating medium (flow) is shut off in the fail-safe position, in cooling applications with FE, cooling is maintained in the fail-safe position.

  • Page 31: Preparation For Installation

    Installation forms can be vented to the atmosphere (to Î Do not insulate valves mounted to com- avoid excess pressure in the device). Further- ply with NACE MR0175 requirements more, the vent plugs allow air intake to pre- and which have nuts and bolts that are vent a vacuum from forming in the device.

  • Page 32: Mounting The External Anti-Rotation Fixture

    Risk of valve damage due to the use of 6. Use a soft-faced hammer or lever press unsuitable tools. to press the sliding washers (309) with Î Only use tools approved by SAMSON their beveled part first (without using any (u AB 0100). lubricant) into the recesses of the clamps (301) as far as they will go.
  • Page 33 Installation Table 5-1: Tightening torques Screw size Tightening torque [Nm] 13. Check and ensure the following: – There is a nominal clearance of 0.5 to 1 mm between the sliding washers and their contact surface on the yoke on each side (see detailed view Y in Fig. 5-3).
  • Page 34 Installation Plug stem Legend Yoke Screws Hanger Travel indicator scale Screws Castellated nut Warning label Ball bearing Fig. 5-2: Overview of yoke assembly with travel indicator scale in the standard version EB 8055 EN...
  • Page 35 Installation Plug stem Legend Stem Lubricant Gleitmo 1763 V Clamps Screws Washers Sliding washers Fig. 5-3: Overview of anti-rotation fixture assembly in the standard version EB 8055 EN...
  • Page 36 Installation b) Special version in valve sizes 8. Thread the stem (9) upwards until the head of the stem rests on the extended DN 50 to 100 actuator stem. See Fig. 5-4 and Fig. 5-5 9. Retract the actuator stem to relieve the stem (9).
  • Page 37 Installation Legend Yoke Screws Hanger Plug stem Travel indicator scale Castellated nut Warning label Holder Screws Washers Fig. 5-4: Overview of yoke assembly with travel indicator scale in the special version EB 8055 EN...
  • Page 38 Installation Plug stem Legend Stem Lubricant Gleitmo 1763 V Clamps Screws Washers Sliding washers Fig. 5-5: Overview of anti-rotation fixture assembly in the special version 5-10 EB 8055 EN...
  • Page 39 Installation Table 5-3: Mounting dimensions for Types 3271 and 3277 Pneumatic Actuators · See Fig. 5-6 for dimensional drawing Trav- Actuator Actuator preloading Dimension when the valve is closed [mm] [cm²] [mm] [mm] DN 50 to 100/NPS 2 to 4 · Special version 3.75 –...
  • Page 40 Installation Trav- Actuator Actuator preloading Dimension when the valve is closed [mm] [cm²] [mm] [mm] DN 200 to 250/NPS 8 to 10 up to seat bore 200 · Standard version 1000 1400-60 87.5 1400-120 2800 5600 DN 250/NPS 10, seat bore 250 and DN 300 to 500/NPS 12 to 20 · Standard version 1000 1400-60 1400-120...
  • Page 41 Installation Ball bearings (standard version only) Fig. 5-6: Dimensional drawing with mounting dimensions for Types 3271 and 3277 Pneumatic Actuators EB 8055 EN 5-13...

  • Page 42: Mounting The Actuator Onto The Valve

    Installation 5.3.2 Mounting the actuator Depending on the version, SAMSON control valves are either delivered with the actuator onto the valve already mounted on the valve or the valve and actuator are delivered separately. When WARNING delivered separately, the valve and actuator Risk of personal injury due to incorrect must be assembled together on site.
  • Page 43 Installation Fig. 5-8: Alignment of the V-port plug in mixing valves (left) and diverting valves (right) b) Aligning the travel indicator and bottom plug uncovered first is cor- rectly aligned. scale Mixing valve: make sure the largest V-shaped port of the V-port plug faces After mounting the actuator, the travel indi- towards the valve outlet AB (see cator scale must be aligned.

  • Page 44: Installing The Valve Into The Pipeline

    Installation 5.3.3 Installing the valve into Flying projectile fragments or the release of process medium under pressure can cause the pipeline serious injury or even death. Before working on the control valve: NOTICE Î Depressurize all plant sections affected Premature wear and leakage due to insuffi- and the valve (including the actuator).

  • Page 45: Leak Test

    Installation bolts protruding from the bottom of the actu- WARNING WARNING ator. Crush hazard arising from actuator and Î Before starting any work on the actuator, plug stem moving. relieve the compression from the pre- Î Do not insert hands or finger into the loaded springs (see associated actuator yoke while the air supply is connected to documentation).

  • Page 46: Travel Motion

    Installation 5.4.3 Fail-safe position Adjusting the packing A label on the bonnet indicates whether an Î Shut off the signal pressure line. adjustable packing is installed (see the Î Check whether the valve moves to the 'Markings on the device' section). fail-safe position (see the 'Design and principle of operation' section).

  • Page 47: 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 appropriately qualified to carry out such tasks. WARNING WARNING Crush hazard arising from actuator and WARNING plug stem moving.
  • Page 48 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).

  • Page 49: 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, the valve plug stem moving. is ready for use. Î Do not insert hands or finger into the yoke while the air supply is connected to the actuator.

  • Page 50: Normal Operation

    Operation 7.1 Normal operation The 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 closed or opened in case of supply air failure.

  • Page 51: Malfunctions

    Malfunctions 8 Malfunctions Read hazard statements, warnings and caution notes in the 'Safety instructions and mea- sures' section. 8.1 Troubleshooting Malfunction Possible reasons Recommended action Actuator and plug stem Actuator is blocked. Check attachment. does not move on de- Remove the blockage. mand.

  • Page 52: Emergency Action

    Malfunctions Malfunction Possible reasons Recommended action The valve leaks to the Defective packing Replace packing (see the 'Servicing' section) or atmosphere (fugitive contact our after-sales service. emissions). Version with adjustable Adjust the packing (see information under packing : packing not 'Adjusting the packing' in the 'Testing the installed  1) tightened correctly...

  • Page 53: Servicing

    Servicing 9 Servicing Î Allow components and pipelines to cool down or warm up to the ambient tem- The work described in this section is only to perature. be performed by personnel appropriately Î Wear protective clothing and safety qualified to carry out such tasks. gloves.
  • Page 54 Risk of valve damage due to the use of WARNING unsuitable tools. Risk of personal injury due to preloaded Î Only use tools approved by SAMSON springs. (u AB 0100). Actuators with preloaded springs are under tension. They can be identified by the long...

  • Page 55: Periodic Testing

    Servicing 9.1 Periodic testing Note The control valve was checked by SAMSON Depending on the operating conditions, before it left the factory. check the valve at certain intervals to prevent − Certain test results certified by SAMSON possible failure before it can occur. Plant op-...
  • Page 56 Servicing Inspection and testing Action to be taken in the event of a negative result: Check the test connection and bellows Put the control valve out of operation (see the seal (if used) for external leakage. 'Decommissioning' section). To repair the bellows seal, WARNING! Risk of personal injury due contact our after-sales service (see the 'Repairs' section).

  • Page 57: Preparing The Valve For Service Work

    Servicing 9.2 Preparing the valve for − The standard or ADSEAL packing is installed in the valve. service work Î To replace parts subject to wear in other valve versions, contact our After-sales WARNING Service. Risk of personal injury due to incorrect removal of the anti-rotation fixture under NOTICE tension.

  • Page 58: Installing The Valve After Service Work

    Servicing 9.3 Installing the valve after 3. Unscrew the castellated nut (92) and take the yoke assembly (60) off the bonnet service work (2). 1. Mount actuator. See associated actuator 4. Undo the body nuts (14) gradually in a documentation and the 'Installation' sec- crisscross pattern.
  • Page 59 Servicing 19. Slide the plug stem (36) together with the 25. Place the yoke assembly (60) on the bon- top plug (5) into the bonnet (2). net (2) and fasten using the castellated nut (92). 20. Place the bonnet (2) and plug stem (36) together with the top plug (5) onto the 26.
  • Page 60 Servicing b) Multi-piece body · Mixing 11. Unscrew the stem connector nut (9) and lock nut (10) from the plug stem. valve 12. Unscrew the threaded bushing (8). 1. DN 15 to 50: unscrew the nut (225) from 13. Pull the plug stem (36) out of the bonnet the bottom end of the plug stem while (2).
  • Page 61 Servicing 1 Body 2 Bonnet 4 Seat 5 Plug 7 Guide bushing 8 Threaded bushing (pack- ing nut) 9 Stem connector nut A26/27 10 Lock nut 14 Body nut 15 Packing 17 Body gasket 20 Seat body 36 Plug stem 60 Yoke assembly 75 Sleeve 76 Sleeve...
  • Page 62 Servicing c) Multi-piece body · Diverting 26. Loosely screw the lock nut (10) and stem connector nut (9) onto the plug stem. valve 27. Place the yoke assembly (60) on the bon- net (2) and fasten using the castellated 1. DN 15 to 50: unscrew the nut (225) from nut (92).
  • Page 63 Servicing 11. Unscrew the threaded bushing (8). 18. Screw in the top and bottom seat (4). Observe tightening torques. 12. Pull the plug stem (36) together with the top plug (5) out of the bonnet (2). 19. Insert a new top gasket (17) into the body.
  • Page 64 Servicing ing a suitable tool. Observe the proper stem. Tighten the nut (225) at the bottom sequence (see section 9.4.3). end of the plug stem while holding the stem connector nut (9) stationary. 25. Firmly press the top plug (5) into the seat (4).

  • Page 65: Version With Insulating Section

    Servicing 9.4.2 Version with insulating section The parts subject to wear in versions with in- sulating section are replaced according to the same principle as for the standard ver- sion. Î Proceed as described in section 9.4.1. The insulating section (21) is installed in- stead of the bonnet (2).

  • Page 66: Sequence Of Packing Parts

    Servicing 9.4.3 Sequence of packing parts a) Standard packing (PTFE) DN 15 to 40 DN 50 to 100 1. Pull the entire packing out of the packing chamber using a suitable tool. 2. Renew damaged parts. Clean the pack- ing chamber thoroughly. 3.
  • Page 67 Servicing DN 15 to 40 DN 50 to 100 15.1 15.1 15.2 15.2 Threaded bushing (packing nut) 15.2 Seals Spring Packing rings Washer Bushing Packing Spacer 15.1 Spacer ring with retaining ring Fig. 9-6: ADSEAL packing EB 8055 EN 9-15...

  • Page 68: 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 document u AB 0100 for details on suitable lubricants.

  • Page 69: 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 appropriately components and process medium being qualified to carry out such tasks. discharged. Î Do not loosen the screw of the test con- nection while the valve is pressurized.
  • Page 70 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. Release any stored energy. (e.g.

  • Page 71: Removal

    Removal 11 Removal WARNING WARNING The work described in this section is only to Risk of personal injury due to residual be performed by personnel appropriately process medium in the valve. qualified to carry out such tasks. While working on the valve, residual medium can flow out of the valve and, depending on its properties, cause personal WARNING...

  • Page 72: Removing The Valve From The Pipeline

    Removal actuator springs is transmitted to the actuator stem and the stem (9). Î 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. Before removing the valve, make sure the fol- lowing conditions are met: −...

  • Page 73: 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 74 12-2 EB 8055 EN...

  • Page 75: 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 8055 EN 13-1...
  • Page 76 13-2 EB 8055 EN...

  • Page 77: Certificates

    Pressure Equipment Directive 2014/68/EU on pages 14-2 to 14-3 − Declaration of conformity in compliance with Machinery Directive 2006/42/EC for Types 3253-1 and 3253-7 Control Valves on page 14-4 − Declaration of incorporation in compli- ance with Machinery Directive 2006/42/EC for the Type 3253 Valve with other actuators other than Types 3271 and 3277 Actuators on...
  • Page 78 Modul A/Module A SAMSON erklärt in alleiniger Verantwortung für folgende Produkte:/For the following products, SAMSON hereby declares under its sole responsibility: Geräte/Devices Bauart/Series Typ/Type Ausführung/Version DIN, Gehäuse GG, DN 65-125, Gehäuse GGG, DN 50-80, Fluide G2, L1, L2 Durchgangsventil/Globe valve...
  • Page 79 EB 8055 EN 14-3...
  • Page 80 14-4 EB 8055 EN...
  • Page 81 EB 8055 EN 14-5...
  • Page 82 14-6 EB 8055 EN...

  • Page 83: Annex

    15 Annex 15.1 Tightening torques, lubricants and tools u AB 0100 for tools, tightening torques and lubricants 15.2 Spare parts 1 Body 60.1 Anti-rotation fixture 2 Bonnet 60.2 Holder 3 Yoke 60.10 Bushing 4 Seat 60.11 Bushing 5 Plug 60.12 Hex screw 7 Guide bushing 60.13 Hex screw 8 Threaded bushing (packing nut)
  • Page 84 Type 3253 (up to DN 40) Mixing/diverting service Single-piece body 15-2 EB 8055 EN...
  • Page 85 60.14 60.13 60.12 60.1 60.11 60.15 60.2 60.17 60.10 60.16 Type 3253 (DN 150) Mixing service Multi-piece body Insulating section EB 8055 EN 15-3...
  • Page 86 60.14 60.13 60.17 60.12 60.1 60.11 60.15 60.2 60.10 60.16 Type 3253 (DN 150) Diverting service Multi-piece body Bellows seal 15-4 EB 8055 EN...

  • Page 87: After-Sales Service

    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 88 15-6 EB 8055 EN...
  • Page 92 EB 8055 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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