Samson 3254 Mounting And Operating Instructions
  1. Manuals
  2. Brands
  3. Samson Manuals
  4. Control Unit
  5. 3254
  6. Mounting and operating instructions

Samson 3254 Mounting And Operating Instructions

Hide thumbs
Table of Contents

Advertisement

Quick Links

Download this manual
EB 8060 EN
Translation of original instructions
Type 3254 Valve with Type 3271 Actuator
Type 3254 Valve · DIN version
In combination with an actuator,
e.g. a Type 3271 or Type 3277 Pneumatic Actuator
Edition January 2021

Advertisement

Table of Contents
loading
Need help?

Need help?

Do you have a question about the 3254 and is the answer not in the manual?

Questions and answers

Related Manuals for Samson 3254

Summary of Contents for Samson 3254

  • Page 1 EB 8060 EN Translation of original instructions Type 3254 Valve with Type 3271 Actuator Type 3254 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 ..............1-4 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 numbers ..................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 ....................15-2 15.3...

  • Page 5: Safety Instructions And Measures

    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 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 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 (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: Notes On The Use Of An Rfid Tag

    Safety instructions and measures 1.4 Notes on the use of an RFID tag The RFID tag is subject to certain restrictions due to its application range (technical specifica- tions). Î Observe the explosion protection certificates of the RFID tag when it is to be used on valves installed in potentially explosive atmospheres.

  • Page 13: Markings On The Device

    2.1 Valve nameplate possible characteristics and options that may appear on a valve nameplate. Only the inscriptions relevant to the ordered Type 3254 Valve actually appear on the nameplate. Fig. 2-1: Inscriptions on the valve nameplate Item Inscription meaning Item Inscription meaning...

  • Page 14: Actuator Nameplate

    Markings on the device 2.4 Label when an adjustable The nameplate (80) is affixed to the yoke of the valve (see Fig. 2-2). packing is installed An instructional label is affixed to the valve when an adjustable packing is installed (see Fig. 2-3).

  • Page 15: Design And Principle Of Operation

    The Type 3254 Valve is a single-seated globe valve. This valve is preferably combined with 3.1 Fail-safe action a SAMSON Type 3271 or Type 3277 Pneu- matic Actuator (see Fig. 3-1).
  • Page 16 Packing Body gasket Travel indicator scale Castellated nut Flange Diaphragm Actuator stem Ring nut Spring Vent plug A26/27 Stem connector clamps Signal pressure connection Fig. 3-1: Type 3254 Valve with Type 3271 Pneumatic Actuator (left) and Type 3277 Pneumatic Actuator (right) EB 8060 EN...

  • Page 17: Versions

    Actuators Insulation In these instructions, the preferable combina- tion with a SAMSON Type 3271 or Control valves can be insulated to reduce Type 3277 Pneumatic Actuator is described. heat energy transfer. The pneumatic actuator (with or without...

  • Page 18: Valve Accessories

    These documents are available on our website at u www.samsongroup.com > Service & Support > Electronic nameplate. Conformity The Type 3254 Valve bears both the CE and EAC marks of conformity. Temperature range Depending on the version, the control valve is designed for a temperature range from –10 to +220 °C.
  • Page 19 Design and principle of operation Dimensions and weights Table 3-1 to Table 3-2 provide an overview of the dimensions and weights of the Type 3254 Valve. The lengths and heights in the dimensional drawings are shown on page 3-6. Dimensions in mm · Weights in kg Table 3-1: Dimensions for Type 3254 Valve ·...
  • Page 20 Design and principle of operation Table 3-2: Dimensions for Type 3254 Valve · Version with insulating section or bellows seal Valve size Insulating section On re- PN 10 to 160 1067 1151 1109  1) quest Height H4 PN 250 to 400 –...
  • Page 21 On request – Up to PN 100 Note The associated actuator documentation applies to actuators, e.g. SAMSON pneumatic actu- ators: u T 8310-1 for Type 3271 or Type 3277 Pneumatic Actuators up to 750 cm² actuator area u T 8310-2 for Type 3271 Actuator with 1000 cm² actuator area and larger u T 8310-3 for Type 3271 Actuator with 1400-60 cm²...
  • Page 22 EB 8060 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 − Protect the piping and any mounted Lifting instructions valve accessories against damage. − Use a hook with safety latch (see − Protect the control valve against moisture Fig. 4-1) to secure the slings from slip- and dirt. ping off the hook during lifting and transporting.
  • Page 26 Shipment and on-site transport b) Version with welding ends − Make sure that the additional sling be- tween the lashing point on the actuator and rigging equipment (hook, shackle 1. Attach one sling to each welding end of etc.) does not bear any load when lifting the body and to the rigging equipment valves with an actuator that has a lifting (e.g.

  • Page 27: 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 longer storage them up.
  • Page 28 EB 8060 EN...

  • Page 29: Installation

    –10 °C 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 30: Preparation For Installation

    Installation Table 5-1: Inlet and outlet lengths Flow rate Inlet length Outlet length a x DN b x DN State of pro- Inlet length Outlet length Valve conditions cess medium Ma ≤ 0.3 0.3 ≤ Ma ≤ 0.7 Ma ≤ 0.3  1) Vapor 0.3 ≤ Ma ≤ 0.7  1) Saturated steam (percentage of condensate > 5 %) Free of cavitation/w < 10 m/s Cavitation producing noise/w ≤ 3 m/s Liquid...

  • Page 31: Mounting The Device

    NOTICE work. Risk of valve damage due to the use of Î Flush the pipelines. unsuitable tools. Î Only use tools approved by SAMSON Note (u AB 0100). The plant operator is responsible for clean- ing the pipelines in the plant. Î For steam applications, dry the pipelines.

  • Page 32: Mounting The External Anti-Rotation Fixture

    The valve must NOTICE be closed beforehand. Impaired functioning due to incorrectly ap- For SAMSON Type 3271 and Type 3277 plied lubricant. Actuators with Type 3273 Hand-operated Î Do not apply any lubricant to the threads Actuator, observe the mounting and operat- of the clamps (301) or the plug stem.
  • Page 33 Installation on each side (see detailed view Y in Fig. 5-2). − The anti-rotation fixture does not get stuck on the yoke and can move free- ly in the direction of travel. 14. Extend the actuator stem again and mount the stem connector clamps. Plug stem Legend Yoke...
  • Page 34 Installation Plug stem Legend Stem Lubricant Gleitmo 1763 V Clamps Screws Washers Sliding washers Fig. 5-2: Overview of anti-rotation fixture assembly in the standard version EB 8060 EN...
  • Page 35 Installation b) Special version for 8. Thread the stem (9) upwards until the head of the stem rests on the extended Series 250 Valves, DN 50 actuator stem. and 100 9. Retract the actuator stem to relieve the stem (9). See Fig. 5-3 and Fig. 5-4 10.
  • Page 36 Installation Legend Yoke Screws Hanger Plug stem Travel indicator scale Castellated nut Warning label Holder Screws Washers Fig. 5-3: Overview of yoke assembly with travel indicator scale in the special version EB 8060 EN...
  • Page 37 Installation Plug stem Legend Stem Lubricant Gleitmo 1763 V Clamps Screws Washers Sliding washers Fig. 5-4: Overview of anti-rotation fixture assembly in the special version EB 8060 EN...
  • Page 38 Installation Table 5-4: Mounting dimensions for Types 3271 and 3277 Pneumatic Actuators · See Fig. 5-5 for dimensional drawing Trav- Actuator Actuator preloading Dimension when the valve is closed [mm] [cm²] [mm] [mm] DN 80 to 100 · Special version 3.75 – – 22.5 118.5 67.5...
  • Page 39 Installation Trav- Actuator Actuator preloading Dimension when the valve is closed [mm] [cm²] [mm] [mm] DN 200 to 250 up to seat bore 200 · Standard version 1000 1400-60 87.5 1400-120 2800 5600 DN 250, seat bore 250 and DN 300 to 500 · Standard version 1000 1400-60 1400-120...
  • Page 40 Installation Ball bearings (standard version only) Fig. 5-5: Dimensional drawing with mounting dimensions for Types 3271 and 3277 Pneumatic Actuators 5-12 EB 8060 EN...

  • Page 41: 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 42 Installation Versions with perforated plug Only one hole is located near the seal facing of perforated plugs with equal percentage characteristic. Depending on the valve size, the hole pattern varies and is partly unsym- Plug metrical. The process medium in the valve stem flows through the holes as soon as the plug is lifted out of the seat.

  • Page 43: Installing The Valve Into The Pipeline

    Installation 2. Loosen the screws on the travel indicator 3. Remove the protective caps from the scale. valve ports before installing the valve. 3. Align the travel indicator scale. 4. Lift the valve using suitable lifting equip- ment to the site of installation (see the 4.

  • Page 44: Testing The Installed Valve

    Installation 5.4 Testing the installed valve Î Wear hearing protection when working near the valve. DANGER Risk of bursting due to incorrect opening of WARNING WARNING pressurized equipment or components. Crush hazard arising from actuator and Valves and pipelines are pressure equipment plug stem moving.

  • Page 45: 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 46: Fail-Safe Position

    Installation Î Apply the maximum and minimum con- trol signals to check the end positions of the valve while observing the movement of the actuator stem. Î Check the travel reading at the travel in- dicator scale. 5.4.3 Fail-safe position Î...

  • 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 'Testing the installed valve' in the 'Installation' sec- tion).

  • Page 49: Operation

    Operation 7 Operation Î Wear hearing protection when working near the valve. Immediately after completing start-up or put- ting the valve back into operation, the valve is ready for use. WARNING WARNING Crush hazard arising from actuator and WARNING plug stem moving. Risk of burn injuries due to hot or cold Î...

  • 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 Remove the blockage. demand.

  • 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 'Installation' section >...

  • 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 Servicing Fig. 9-1: Standard version of Type 3254 with Type 3271 Actuator (left) and Type 3254 in version with insulating section (right) EB 8060 EN...

  • Page 58: Preparing The Valve For Service Work

    Servicing Legend for Fig. 9-1 Body Stud bolt Bonnet Yoke Packing Seat Body gasket Plug (with plug stem) Insulating section Guide bushing Castellated nut Threaded bushing (packing nut) Expansion sleeve (for PN 63 to 400) Stem connector nut Flange Lock nut 9.2 Preparing the valve for 2.

  • Page 59: Installing The Valve After Service Work

    Servicing 9.4.1 Replacing the top gasket − Replace the bottom gasket as described in section 9.4.2. − Replace the packing (see section 9.4.3) NOTICE − Replace the seat and plug (see sec- Risk of control valve damage due to incor- tion 9.4.4) rect servicing. Î...

  • Page 60: Replacing The Bottom Gasket

    Servicing es the flow first faces toward the valve See relevant information under 'Mount- outlet. ing the actuator onto the valve' in the 'In- stallation' section. See relevant information under 'Mount- ing the actuator onto the valve' in the 'In- 6.

  • Page 61: Replacing The Packing

    Servicing 6. Place the flange (100) onto the body. 4. Unscrew the stem connector nut (9) and Make sure that the plug stem (5) is prop- lock nut (10) from the plug stem. erly seated in the guide. 5. Unscrew the threaded bushing (8). 7.
  • Page 62 Servicing 8 Threaded bushing 11 Spring 12 Washer 16 Packing ring 19 Spacer Fig. 9-2: Standard packing: DN 15 to 40 (left) and DN 50 to 100 (right) ly in a crisscross pattern. Observe tight- ing a suitable tool. Observe the proper ening torques. sequence (see Fig. 9-3).
  • Page 63 Servicing 15.1 15.1 15.2 15.2 8 Threaded bushing 15.2 Seal 11 Spring 16 Packing ring 12 Washer 18 Bushing 15 Packing (entire) 19 Spacer 15.1 Spacer ring with retaining ring Fig. 9-3: ADSEAL packing: DN 15 to 40 (left) and DN 50 to 100 (right) b) Version with insulating 2.
  • Page 64 Servicing 6. Pull the plug with plug stem (5) out of the 12. Carefully slide the packing parts over the insulating section (21). plug stem into the packing chamber us- ing a suitable tool. Observe the proper 7. Pull the entire packing out of the packing sequence (see Fig. 9-2).
  • Page 65 Servicing Fig. 9-4: Standard version of Type 3254 with Type 3271 Actuator (left) and Type 3254 in version with insulating section (right) EB 8060 EN 9-13...

  • Page 66: Replacing The Seat And Plug

    Servicing Insert the wire of the red spacer ring NOTICE (15.1) into the groove of the retaining Risk of damage to the facing of the seat ring. and plug due to incorrect servicing. Slide the retaining ring over the plug Î...
  • Page 67 Servicing 11. Apply a suitable lubricant to the thread 18. Screw in the threaded bushing (8) and and the sealing cone of the new seat. tighten it. Observe tightening torques. 12. Screw in the seat (4). Observe tightening 19. Place yoke (3) on the bonnet (2) and fas- torques.

  • Page 68: Ordering Spare Parts And Operating Supplies

    15. Place the insulating section (21) together Contact your nearest SAMSON subsidiary with the plug stem and plug (5) onto the or SAMSON's After-sales Service for infor- body (1). mation on spare parts, lubricants and tools. Version with V-port plug: place the insu-...

  • 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 2. Completely drain the pipelines and the same position for a long time), re- valve. lease any stored energy in the actuator 3. Disconnect and lock the pneumatic air (e.g. spring compression). See associat- supply to depressurize the actuator.

  • 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 springs is transmitted to the actuator stem 3. Remove the valve from the pipeline (see and the stem (9). the 'Shipment and on-site transport' sec- Î First remove the actuator from the valve tion). or ensure it cannot transmit any forces to 11.2 Removing the actuator the actuator stem before removing the anti-rotation fixture on the plug stem.

  • 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 8060 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 8060 EN 13-1...
  • Page 76 13-2 EB 8060 EN...

  • Page 77: Certificates

    Pressure Equipment Directive 2014/68/EU on page 14-2 − Declaration of conformity in compliance with Machinery Directive 2006/42/EC 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 3271 and 3277 Actuators on...
  • Page 78 14-2 EB 8060 EN...
  • Page 79 EB 8060 EN 14-3...
  • Page 80 14-4 EB 8060 EN...

  • Page 81: Annex

    Annex 15 Annex 15.1 Tightening torques, lubri- cants and tools u AB 0100 for tools, tightening torques and lubricants EB 8060 EN 15-1...

  • Page 82: Spare Parts

    Annex 15.2 Spare parts 1 Body 46 Gasket  1) 2 Bonnet 47 Support  1) 3 Yoke 48 Hex screw  1) 4 Seat 49 Hex screw  1) 5 Plug 50 Lock  1) 7 Guide bushing 51 Guide (several guides only for  1) version with graphite seal) 8 Threaded bushing (packing nut)
  • Page 83 EB 8060 EN 15-3...

  • Page 84: 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 EB 8060 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...

Table of Contents