Samson EB 51b Mounting And Operating Instructions
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Samson EB 51b Mounting And Operating Instructions

Samson EB 51b Mounting And Operating Instructions

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MOUNTING AND
OPERATING INSTRUCTIONS
EB 51b
Translation of the original manual
Shut-off Ball valve BR 51b • DIN and ANSI version
to combine with actuators
February 2024 edition
PFEIFFER Chemie-Armaturenbau GmbH · Hooghe Weg 41 · 47906 Kempen · Germany
Phone: +49 2152 2005-0 · Fax: +49 2152 1580
sales-pfeiffer-de@samsongroup.com · www.pfeiffer-armaturen.com

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  • Page 1 MOUNTING AND OPERATING INSTRUCTIONS EB 51b Translation of the original manual Shut-off Ball valve BR 51b • DIN and ANSI version to combine with actuators February 2024 edition PFEIFFER Chemie-Armaturenbau GmbH · Hooghe Weg 41 · 47906 Kempen · Germany Phone: +49 2152 2005-0 ·...
  • Page 2 Note regarding this installation and operating manual This Installation and Operating Manual (EB) provides guidance for safe assembly and operation. The notes and instructions in this EB are binding when handling PFEIFFER devices. The fi gures and illustrations in this EB are ex- amples and must therefore be considered as such.

  • Page 3: Table Of Contents

    Content Content Safety instructions and safety measures Notes regarding possible severe personnel injury Notes regarding possible personnel injury Notes regarding possible property damage Warning notes on the device Markings on the device Type plate 2.1.1 Actuator type plate Material identifi cation Design and principle of operation Variants Additional fi...
  • Page 4 Content Start-up Operation Malfunction Detecting and rectifying errors Carrying out emergency measures Servicing Periodic tests Maintenance work 9.2.1 Replacing the seat rings and ball Ordering spare parts and consumables 10 Decommissioning 10-1 11 Removal 11-1 11.1 Removing the ball valve from the pipe 11-1 11.2 Disassembling the actuator...

  • Page 5: Safety Instructions And Safety Measures

    Safety instructions and safety measures − Specialist personnel in terms of this installation and operating Safety instructions and safety measures manual are persons who, on the basis of their vocational ed- ucation, knowledge and experience and knowledge of the Intended use relevant standards, are capable of evaluating the assigned The BR 51b shut-off ball valve with dead space relief is manually tasks and identifying possible hazards.

  • Page 6: Notes Regarding Possible Severe Personnel Injury

    Safety instructions and safety measures − An actuator unit that is subsequently installed on the ball DANGER valve is adapted to the ball valve and the max. torque is ob- served, and is correctly adjusted in the end positions, and in Hazards and damage due to unsuitable ball valves! particular in the opening position of the ball valve.

  • Page 7: Notes Regarding Possible Property Damage

    Safety instructions and safety measures 1.3 Notes regarding possible property WARNING damage Danger of injury due to preloaded springs! Ball valves that are equipped with preloaded actuator springs NOTE are under mechanical tension. Before working on the actuator, release the compression from Damage to the ball valve due to contamination! the preloaded springs, see the corresponding actuator docu- Contamination (e.g.

  • Page 8: Warning Notes On The Device

    Safety instructions and safety measures 1.4 Warning notes on the device Warning of moving parts Fig. 1-1: Warning of moving parts There is a danger of crushing due to the rotary movements of the actuator- and switching shaft when reaching into the yoke as long as the pneumatic power is connected to the actuator.

  • Page 9: Markings On The Device

    Markings on the device Markings on the device Each ball valve usually has the following marking. Table 2-1: Marking on the type plate and on the body of the ball valve Pos. Marking Remark Manufacturer PFEIFFER Address see Chapter “15.3 Service” Valve type BR (and number value) e.

  • Page 10: Type Plate

    Markings on the device 2.1 Type plate 2.1.1 Actuator type plate See the corresponding actuator documentation. 2.2 Material identifi cation The ball valves are marked on the body with the material specifi - cation; see “Table 2-1: Marking on the type plate and on the body of the ball valve”.

  • Page 11: Design And Principle Of Operation

    Design and principle of operation Fail-safe position Design and principle of operation Depending on assembly position of the pneumatic actuator, the valve has two fail-safe positions which become effective when the Function and principle of operation air pressure in the actuator is relieved or when the supply air The BR 51b ball valves permits full pressure fl...

  • Page 12: Attachments

    − Control shaft extension (100 mm) − Pneumatic and electric multi-turn actuator 3.5.1 Assembly of the ball valve up to − Positioner, Samson 3730 for ESD application DN 150/NPS8 − Limit switch − Solenoid valves Info −...
  • Page 13 Design and principle of operation Fig. 3-2: Sectional drawing of the shut-off ball valve up to DN 150 / NPS6 Table 3-1: Parts list of the shut-off ball valve up to DN 150 / NPS6 Item Description Item Description Item Description Main body Bearing bush...
  • Page 14 Design and principle of operation Insert the jacketed disc spring (9) into the body chamber in Place the stuffi ng box fl ange (4) over the control shaft (5) on- the main body (1). to the main body (1). Press the seat ring (8a) up to the disc spring. Lightly grease the screws (32).

  • Page 15: Assembly Of The Dn 200/Nps8 Ball Valve

    Design and principle of operation Insert the thrust ring and compression springs into the body NOTE chamber of the main body (1). Damage due to improper assembly! Press the seat ring (8a) up to the thrust ring. Pay attention to not twist the control shaft and bearing bush. Push the bearing bush (50) with a slight rotary movement on- The permissible torque for retightening the connection of the to the control shaft (5).
  • Page 16 Design and principle of operation Fig. 3-3: Sectional drawing of the shut-off ball valve DN 200 / NPS8 Table 3-2: Parts list of the shut-off ball valve DN 200 / NPS8 Item Description Item Description Item Description Main body Screw / Stud bolt Bearing Side body Ring...
  • Page 17 Design and principle of operation Press the seat ring (8b) up to the thrust ring. Evenly adjust the stuffi ng box fl ange (4) with the screws (32) and tighten in a criss-cross pattern. Place the side body (2) with the preassembled seat ring (8b) on the main body (1).
  • Page 18 Design and principle of operation EB 51b_EN February 2024 edition Subject to technical changes...

  • Page 19: Shipment And On-Site Transport

    Shipment and on-site transport Shipment and on-site transport WARNING The work described in this chapter may only be performed by Danger of injury due to the tipping of the ball valve! specialist personnel qualifi ed to perform the corresponding task. Observe the centre of gravity of the ball valve.

  • Page 20: Lifting Points On The Body

    Shipment and on-site transport Fig. 4-4: Lifting points on the ball valve 4.3.3 Lifting points on the body Fasten the sling such that it can be removed again after in- stallation in the pipe. Fasten a lifting sling to each fl ange of the housing and on the Avoid swinging and tipping the ball valve.

  • Page 21: Storing The Ball Valve

    Shipment and on-site transport Move the ball valve at a constant speed to the installation site. Install the ball valve in the pipe, see chapter 5.4 After installation in the pipe: check that the fl anges are fi rmly tightened and that the ball valve holds in the pipe. Remove the lifting slings.
  • Page 22 Shipment and on-site transport EB 51b_EN February 2024 edition Subject to technical changes...

  • Page 23: Installation

    Installation When connecting the attachments, make sure that they can Installation be accessed from the operator level safely and easily. The work described in this chapter may only be performed by specialist personnel qualifi ed to perform the corresponding task. The following instructions apply additionally for ball valves.

  • Page 24: Installing The Ball Valve In The Pipe

    Installation The connection ends of the pipe must align with the ball valve WARNING connections and have plane-parallel ends. Danger and damage due to heavy actuator units! The connection data for the actuator unit must match the con- Actuators that are heavier than the weight of the ball valve can trol data.

  • Page 25: Checking The Assembled Ball Valve

    Installation Info WARNING For ball valves spring-loaded on one side: Danger of crushing due to moving actuator- and control shaft! To obtain the desired functionality with ball valves spring-loaded Do not reach into the yoke as long as the pneumatic power is on one side with a fl...

  • Page 26: Rotary Movement

    Installation Info The plant operator is responsible for performing the pressure test. After Sales Service at PFEIFFER can provide you with support for the planning and implementation of a pressure test specifi c to your plant. 5.5.3 Rotary movement The rotary movement of the actuator- and control shaft must be linear without any jerky movements.

  • Page 27: Start-Up

    Start-up Commissioning/recommissioning Start-up − Open the ball valves slowly in the pipe. Opening slowly pre- The work described in this chapter may only be performed by vents a sudden increase in pressure and a resulting high fl ow specialist personnel qualifi ed to perform the corresponding task. speed that damages the ball valve.
  • Page 28 Start-up EB 51b_EN February 2024 edition Subject to technical changes...

  • Page 29: Operation

    Operation of extensions to increase the actuation torque is not permit- Operation ted. As soon as the commissioning/recommissioning work is com- − In the case of shut-off ball valves with a hand lever, the posi- plete, see Chapter “6 Commissioning”, the shut-off ball valve is tion of the hand lever indicates the location of the bore in the ready for operation.
  • Page 30 Operation EB 51b_EN February 2024 edition Subject to technical changes...

  • Page 31: Malfunction

    Malfunction Malfunction When rectifying the faults, chapter “1 Safety instructions and safety measures” must be observed. 8.1 Detecting and rectifying errors Type of fault Possible cause Measures Leaks in the pipe connection The fl ange connection of the Tighten the fl ange screws. ball valve is leaky NOTE An excessive tightening torque when retightening the fl...

  • Page 32: Carrying Out Emergency Measures

    Malfunction Type of fault Possible cause Measures Problems in the actuator unit The pneumatic actuator must Disconnect the connection to the control pressure. be removed Remove the actuator from the ball valve (observe the “Safety instructions and safety measures”, see the included actuator unit manuals).

  • Page 33: Servicing

    Servicing Servicing NOTE The work described in this chapter may only be performed by Damage to the ball valve due to excessively high or low tight- specialist personnel qualifi ed to perform the corresponding task. ening torques! The following documents are required in addition for the mainte- The ball valve components must be tightened with specifi...

  • Page 34: Maintenance Work

    Servicing 9.3 Ordering spare parts and consumables Measures in the case of a negative Test test result Information about spare parts, lubricants and tools can be re- Check the rotary movement of If the actuator- and control shaft are ceived from the After Sales Service at PFEIFFER. the actuator- and control shaft blocked, remove the blockage.

  • Page 35: Decommissioning

    Decommissioning To decommission the shut-off ball valve for maintenance and re- 10 Decommissioning pair work or for disassembly, perform the following steps: The work described in this chapter may only be performed by Close the valves upstream and downstream of the ball valve specialist personnel qualifi...
  • Page 36 Decommissioning EB 51b_EN 10-2 February 2024 edition Subject to technical changes...

  • Page 37: Removal

    Removal 11 Removal WARNING The work described in this chapter may only be performed by If a used valve is sent to PFEIFFER for service: specialist personnel qualifi ed to perform the corresponding task. Decontaminate the valves properly in advance. WARNING Danger of burning due to hot or cold components and pipe! When returning a used valve, include the safety data sheet...
  • Page 38 Removal EB 51b_EN 11-2 February 2024 edition Subject to technical changes...

  • Page 39: Repairs

    Repairs Disassemble the ball valve to remove the packing. For this pur- 12 Repairs pose, observe Chapter “1 Safety instructions and safety meas- If the operation of the Shut-off ball valve is no longer compliant ures”. or if it does not work at all, it is defective and must be repaired Place the ball valve on an even and clean work surface so or replaced.
  • Page 40 Repairs Fig. 12-1: BR 51b Ball valve EB 51b_EN 12-2 February 2024 edition Subject to technical changes...

  • Page 41: Replacing The Seat Ring Of The Ball Dn 200 / Nps8

    Repairs Table 12-1: Parts list Item Description Item Description Item Description Main body O-ring Sealing ring chamber (outside) Side body Bearing bush Sealing ring chamber (inside) Ball Bearing bush Sealing ring Stuffi ng box fl ange Adapter body Thrust ring Control shaft Ring sleeve Bush...

  • Page 42: Additional Repairs

    Repairs Carefully remove the ball (3) with ring screws from the main body (1) Screw ring screws into the 4 thread bores for the bearing shells (23). Check the seat rings and the ball as well as all plastic and graphite parts for damage and, in the case of doubt, replace them.

  • Page 43: Disposal

    Disposal 13 Disposal For disposal, observe the local, national and international regulations. Do not dispose of old components, lubricant and hazardous materials with domestic waste. EB 51b_EN 13-1 February 2024 edition Subject to technical changes...
  • Page 44 Disposal EB 51b_EN 13-2 February 2024 edition Subject to technical changes...

  • Page 45: Certifi Cates

    Certifi cates 14 Certifi cates The declaration of conformity is available on the following pages: − Declaration of conformity according to Pressure Equipment Directive 2014/68/EU for automated valves, see page 14-2. − Declaration of conformity according to Pressure Equipment Directive 2014/68/EU for manually operated valves, see page 14-3.
  • Page 46 Certifi cates EB 51b_EN 14-2 February 2024 edition Subject to technical changes...
  • Page 47 Certifi cates EB 51b_EN 14-3 February 2024 edition Subject to technical changes...
  • Page 48 Certifi cates EB 51b_EN 14-4 February 2024 edition Subject to technical changes...
  • Page 49 Certifi cates EB 51b_EN 14-5 February 2024 edition Subject to technical changes...
  • Page 50 Certifi cates EB 51b_EN 14-6 February 2024 edition Subject to technical changes...

  • Page 51: Annex

    Annex Table 15-2: Stuffi ng box tightening torques 15 Annex Nominal size Qty. Thread (32) Tightening torque 1) 2) 15.1 Tightening torques, lubricant and tools ½ 8.8 Nm 15.1.1 Tightening torques 8.8 Nm 21.5 Nm Info 44 Nm The tightening torques stated in the tables can only be under- 44 Nm stood as very rough and non-binding guide values and refer to a coeffi...

  • Page 52: Lubricant

    Annex 15.1.1.5 Flange connection 15.1.2 Lubricant Table 15-8: Recommended lubricant Info Required tightening torques for assembly for fl anges according to Temperature range Lubricant DIN EN 1092-1 type 11 and connecting elements (e.g. screws, Screws and nuts -10 ... +200°C Heavy-duty grease paste (e.g.

  • Page 53: Spare Parts

    Annex 15.2 Spare parts PFEIFFER recommends spare part sets for “Commissioning” and for “2-year operation”, see Chapter: − „15.2.1 Spare parts of the ball valve up to DN 150 / NPS6“ auf Seite 15-4 and − „15.2.2 Spare parts of the ball valve DN 200 / NPS8“ auf Seite 15-6.

  • Page 54: Spare Parts Of The Ball Valve Up To Dn 150 / Nps6

    Annex 15.2.1 Spare parts of the ball valve up to DN 150 / NPS6 Fig. 15-1: Exploded drawing of the ball valve up to DN 150 / NPS6 EB 51b_EN 15-4 February 2024 edition Subject to technical changes...
  • Page 55 Annex Table 15-9: Recommend spare parts for the ball valve up to DN 150 / NPS6 In the spare parts set for In the spare parts for 2 year Item Description Material commissioning operation 1.4408 Main body 1.4571 1.4408 Side body 1.4571 1.4404 1.4408...

  • Page 56: Spare Parts Of The Ball Valve Dn 200 / Nps8

    Annex 15.2.2 Spare parts of the ball valve DN 200 / NPS8 Fig. 15-1: Exploded drawing of the ball valve DN 200 / NPS8 EB 51b_EN 15-6 February 2024 edition Subject to technical changes...
  • Page 57 Annex Table 15-10: Recommend spare parts for the ball valve up to DN 150 / NPS6 In the spare parts set for In the spare parts for 2 year Item Description Material commissioning operation 1.4408 Main body 1.4571 1.4408 Side body 1.4571 1.4404 1.4408...

  • Page 58: Service

    Annex 15.3 Service For maintenance and repair work as well as malfunctions or de- fects, contact the After Sales Service at PFEIFFER for support. E-mail The After Sales Service can be reached at the e-mail address “sales-pfeiffer-de@samsongroup.com”. Necessary data Provide the following information in the case of questions and for troubleshooting: −...
  • Page 59 EB 51b_EN February 2024 edition Subject to technical changes...
  • Page 60 PFEIFFER Chemie-Armaturenbau GmbH Hooghe Weg 41 · 47906 Kempen · Germany Phone: +49 2152 2005-0 · Fax: +49 2152 1580 E-Mail: sales-pfeiffer-de@samsongroup.com · Internet: www.pfeiffer-armaturen.com EB 51b_EN February 2024 edition Subject to technical changes...

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