Samson BR 28a/x Mounting And Operating Instructions

Metering ball valve din and ansi version

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MOUNTING AND

OPERATING INSTRUCTIONS

EB 28ax

Translation of the original manual

Metering ball valve BR 28a/x • DIN and ANSI version

to combine with actuators

for installation in piggable pipes

November 2023 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 28ax Translation of the original manual Metering ball valve BR 28a/x • DIN and ANSI version to combine with actuators for installation in piggable pipes November 2023 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 metering ball valve from the pipe 11-1 11.2 Disassembling the actuator...
Page 5: Safety Instructions And Safety Measures
Intended use relevant standards, are capable of evaluating the assigned The BR 28a/x piggable metering ball valve is manually operated tasks and identifying possible hazards. in combination with an actuator for the regulation of the volume ﬂ...
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 NOTE Damage to the ball valve due to unsuitable tools! Unsuitable tools can damage the ball valve. Suitable tools are required to work on the ball valve, see Chapter “15.1.3 Tools”. Damage to the ball valve due to unsuitable lubricants! Unsuitable lubricants can corrode and damage the surface.
Page 9: Markings On The Device
Remark Manufacturer PFEIFFER Address see Chapter “15.3 Service” Valve type BR (and number value) e.g. BR 28a/x = Series 28a/x, see the PFEIFFER catalogue Body material e.g. 1.4571 Material standard acc. to DIN EN 10272 Size DN (and number value) Number value in [mm], e.g.
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 The control shaft is externally equipped with a manual gearbox, Design and principle of operation or optionally with a pneumatic quarter turn actuator. Characteristics: Fail-safe position − Inside diameter of pipe, according to DIN 2430 Because of the valve application in a pigging pipe-system, the −...
Page 12: Attachments
(1) through the − The documentation for the special metering ball valves opening for the control shaft. BR 28a/x that are not described in this chapter can be request- ed from PFEIFFER. NOTE The sealing surface of the control shaft (4) must not be damaged.
Page 13 Design and principle of operation Fig. 3-1: Sectional drawing of metering ball valve Table 3-1: List of parts Item Description Item Description Main body Sealing Side body Disc spring set Ball V-ring packing Control shaft Disc spring Stufﬁ ng box ﬂ ange Disc spring jacket Bearing bush Screw / Stud bolt...
Page 14: Final Assembly Of The Metering Ball Valve
Design and principle of operation 3.5.4 Final assembly of the metering ball valve Turn the side body (2) until the bores of both body parts (1 and 2) are aligned with each other. After applying grease to the screws (15) both parts (1 and 2) are screwed together, evenly and in alternating pattern.
Page 15: 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 metering ball valve! specialist personnel qualiﬁ ed to perform the corresponding task. Observe the centre of gravity of the ball valve.
Page 16: Lifting Points On The Body
Shipment and on-site transport Fig. 4-2: Lifting points on the metering 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 17: Storing The Metering 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 18 Shipment and on-site transport EB 28ax_EN November 2023 edition Subject to technical changes...
Page 19: 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 20: Installing The Metering Ball Valve In The Pipe
Installation WARNING DANGER Danger and damage due to high external loads on an actuator Danger due to exceeding the limits of use! unit! Exceeding the limits of use can pose a danger to the user and Actuators are not “stepladders”. cause damage to the pipe system.
Page 21: Installing The Metering Ball Valve
Installation 5.4.2 Installing the metering ball valve WARNING Close the ball valve in the pipe for the duration of the instal- Danger of injury due to escaping exhaust air! lation. During operation, when regulating or when opening and closing Remove the protective caps on the ball valve openings prior the ball valve, exhaust air can escape, for example from the ac- to installation.
Page 22: Fail-Safe Position
Installation Set the maximum and minimum control signal in succession to check the end positions of the ball valve. Check the display on the position indicator. 5.5.4 Fail-safe position Close the signal pressure line. Check whether the ball valve moves to the fail-safe position, see “Fail-safe positions in Chapter “3 Design and principle of operation”.
Page 23: 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 24 Start-up EB 28ax_EN November 2023 edition Subject to technical changes...
Page 25: Operation
Operation − For the manual operation or manual override of the actuator Operation (if present), normal manual forces are sufﬁ cient and the use As soon as the commissioning/recommissioning work is com- of extensions to increase the actuation torque is not permit- plete, see Chapter “6 Commissioning”, the shut-off ball valve is ted.
Page 26 Operation EB 28ax_EN November 2023 edition Subject to technical changes...
Page 27: 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. metering ball valve is leaky NOTE An excessive tightening torque when retightening the ﬂ...
Page 28: 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 29: 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 30: Maintenance Work
Servicing Measures in the case of a negative Test test result Check the rotary movement of If the actuator- and switching shaft are the actuator- and switching blocked, remove the blockage. shaft for smooth movement. WARNING! If the actuator- and switch- ing shaft are blocked (e.g.
Page 31: Decommissioning
Decommissioning To decommission the metering 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 32 Decommissioning EB 28ax_EN 10-2 November 2023 edition Subject to technical changes...
Page 33: 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 34 Removal EB 28ax_EN 11-2 November 2023 edition Subject to technical changes...
Page 35: Repairs
Repairs Loosen the screws (17) and carefully remove stufﬁ ng box 12 Repairs ﬂ ange (5). If the operation of the metering ball valve is no longer compliant Remove the disc springs from the set of spring washers (11). or if it does not work at all, it is defective and must be repaired Remove the V-ring packing (12).
Page 36 Repairs Fig. 12-1: Sectional drawing of metering ball valve BR 28a/x Table 12-1: List of parts Item Description Item Description Main body Sealing Side body Disc spring set Ball V-ring packing Control shaft Disc spring Stufﬁ ng box ﬂ ange...
Page 37 Repairs − Manufacturer number − Metering ball valve type − Article number − Nominal size and version of the metering ball valve − Manual valve/automated valve − Medium (designation and consistency) − Medium pressure and temperature − Flow rate in m³/h −...
Page 38 Repairs EB 28ax_EN 12-4 November 2023 edition Subject to technical changes...
Page 39: 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 28ax_EN 13-1 November 2023 edition Subject to technical changes...
Page 40 Disposal EB 28ax_EN 13-2 November 2023 edition Subject to technical changes...
Page 41: Certifi Cates
14-3. − Declaration of conformity for completed machinery accord- ing to Machinery Directive 2006/42/EC for the metering ball valve BR 28a/x, see page 14-4. − Declaration of conformity for partly completed machinery ac- cording to Machinery Directive 2006/42/EC for metering ball valve BR 28a/x, see page 14-5.
Page 42 Certiﬁ cates EB 28ax_EN 14-2 November 2023 edition Subject to technical changes...
Page 43 Certiﬁ cates EB 28ax_EN 14-3 November 2023 edition Subject to technical changes...
Page 44 Certiﬁ cates EB 28ax_EN 14-4 November 2023 edition Subject to technical changes...
Page 45 Certiﬁ cates EB 28ax_EN 14-5 November 2023 edition Subject to technical changes...
Page 46 Certiﬁ cates EB 28ax_EN 14-6 November 2023 edition Subject to technical changes...
Page 47: Annex
Annex 15 Annex 15.1.1.3 Flange connection 15.1 Tightening torques, lubricant and tools Info Required tightening torques for assembly for ﬂ anges according to DIN EN 1092-1 type 11 and connecting elements (e.g. screws, 15.1.1 Tightening torques threaded pins) made of 25CrMo4 / A4-70 or a comparable strength.
Page 48: Lubricant
Annex 15.1.2 Lubricant 15.2 Spare parts PFEIFFER recommends spare part sets for “Commissioning” and Table 15-6: Recommended lubricant for “2-year operation”, see Chapter: Temperature range Lubricant − „15.2.1 Spare parts of the metering ball valve on Side 15-3 Screws and nuts -10 ...
Page 49: Spare Parts Of The Metering Ball Valve
Annex 15.2.1 Spare parts of the metering ball valve Fig. 15-1: Exploded drawing of the metering ball valve Table 15-7: Recommend spare parts for the metering ball valve Spare part set Item Description Material Commissioning 2-year operation Main body 1.4571 1.4408 •...
Page 50: 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 51 EB 28ax_EN November 2023 edition Subject to technical changes...
Page 52 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 28ax_EN November 2023 edition Subject to technical changes...

Samson BR 28a/x Mounting And Operating Instructions

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