Samson BR 28e Mounting And Operating Instructions

Pig loading ball valve to combine with manual gearboxes for installation in piggable pipes

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Installation and operating manual (56 pages)

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MOUNTING AND

OPERATING INSTRUCTIONS

EB 28e

Translation of the original manual

Pig loading ball valve BR 28e • DIN and ANSI version

to combine with manual gearboxes

for installation in piggable pipes

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 28e Translation of the original manual Pig loading ball valve BR 28e • DIN and ANSI version to combine with manual gearboxes for installation in piggable pipes 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 seal 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 − Protective garments, protective gloves and eye protection The BR 28e pig loading ball valve is manually operated and is when using hot, cold, aggressive and/or corrosive media. used for removing, or inserting the pigs into the pigging pipe system.
Page 6: Notes Regarding Possible Severe Personnel Injury
Safety instructions and safety measures − PFEIFFER is contacted in the case of abnormal operating con- DANGER ditions, such as vibrations, hydraulic shock, cavitation and also small amounts of solid matter in the medium, especially Risk of bursting of the pressure equipment! abrasive matter.
Page 7: Notes Regarding Possible Property Damage
Safety instructions and safety measures WARNING NOTE Hazards due to incorrect ball valve use! Deviation of the breakaway and actuating forces due to The incorrect use of the ball valve can represent a hazard for the non-actuation of the ball valve! user and cause damage to the pipe system that are then no Depending on the period of time of non-actuation, the breaka- longer the responsibility of PFEIFFER.
Page 8 Safety instructions and safety measures EB 28e_EN February 2024 edition Subject to technical changes...
Page 9: Markings On The Device
Remark Manufacturer PFEIFFER Address see Chapter “15.3 Service” Valve type BR (and number value) e.g. BR 28e = Series 28e, 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
Further attachments are available according to customer speciﬁ Function and principle of operation cations. The pig loading ball valves of BR 28e are used for removing, or inserting the pigs into the pigging pipe system. The ball (3) with a slight tapered blind bore, is rotatable around 3.4 Technical data...
Page 12: Preparation Of The Assembly
3.5 Pig loading ball valve assembly vertical to the working surface. The BR 28e pig loading ball valves in nominal sizes up to DN 80 Now carefully insert the ball (3). have design differences to the ball valves from DN 100, so that Place the sealing (14) in the turned recess in the main body they cannot be included in a construction manual.
Page 13 Design and principle of operation Fig. 3-1: Sectional drawing of pig loading ball valve DN 50 ... 80 Table 3-1: List of parts Item Description Item Description Main body Disc spring set Side body Disc spring Ball Disc spring jacket Control shaft Sealing Stufﬁ...
Page 14 Design and principle of operation After applying grease to the screws (16) align and tighten Info evenly in alternating pattern. The permissible torque for tightening the trunnion can be found in Table 15-4 in Chapter “15.1.1 Tightening torques”. Info The permissible torque for tightening the stufﬁ ng box can be found in Table 15-2 in Chapter “15.1.1 Tightening torques”.
Page 15 Design and principle of operation Fig. 3-2: Sectional drawing of pig loading ball valve DN 100 ... 200 Table 3-2: List of parts Item Description Item Description Main body Screw Side body Screw plug Ball Screw plug Control shaft Screw Stufﬁ...
Page 16 Design and principle of operation Place the disc spring jacket (13) on the disc spring (12). Info Pull on the disc spring jacket so that the long side of the jacket is positioned towards the body and the short side towards the seat ring.
Page 17: 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 pig loading ball specialist personnel qualiﬁ ed to perform the corresponding task. valve! Observe the centre of gravity of the ball valve.
Page 18: Lifting Points On The Bracket
Shipment and on-site transport 4.3.3 Lifting points on the bracket and side body Fasten one lifting sling each to the bracket and the ﬂ ange of the side body and on the suspension element (e.g. hook) of the crane or forklift, see Fig. 4-1. When doing so, ensure the safety, bearing capacity and length of the lifting slings Lift the ball valve carefully.
Page 19: Installation
Installation Perform the following steps after receiving the goods: Installation Check the scope of supply. Compare the delivered goods The work described in this chapter may only be performed by with the delivery note. specialist personnel qualiﬁ ed to perform the corresponding task. Check the supply for transport damage.
Page 20: General
Installation Prior to installation, the ball valve and the connected pipe NOTE must be carefully cleaned of any contamination, in particular solid foreign matter. Damage to the pig loading ball valve due to the incorrect set- ting of the end stops! The sealing surfaces on the ﬂ...
Page 21: Functional Test
Installation 5.5 Checking the assembled pig loading ball valve 5.5.1 Functional test WARNING Danger of injury due to pressurised components and escaping medium! Do not loosen the screw of an optional test connection while the ball valve is pressurised. Danger of crushing due to moving actuator- and control shaft! Do not allow the jamming of objects in the yoke to hinder the operation of the actuator- and control shaft.
Page 22 Installation EB 28e_EN February 2024 edition Subject to technical changes...
Page 23: Start-Up
Start-up Start-up The work described in this chapter may only be performed by specialist personnel qualiﬁ ed to perform the corresponding task. WARNING Danger of burning due to hot or cold components and pipe! Ball valve components and pipes can become very hot or very cold during operation and cause burns upon contact.
Page 24 Start-up EB 28e_EN February 2024 edition Subject to technical changes...
Page 25: Operation
Operation Operation DANGER Danger of injury due to jerky operation of the pig loding ball 7.1 General valve! As soon as the commissioning/recommissioning work is com- The failure to observe these warnings can cause extreme danger plete, see Chapter “6 Commissioning”, the pig loading ball valve for persons or for the pipe system.
Page 26 Operation EB 28e_EN February 2024 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. pig loading ball valve is leaky NOTE An excessive tightening torque when retightening the ﬂ...
Page 28 Malfunction Recommissioning after faults See Chapter “6 Commissioning”. EB 28e_EN February 2024 edition Subject to technical changes...
Page 29: Servicing
Servicing Servicing Info The work described in this chapter may only be performed by The pig loading ball valve was checked by PFEIFFER prior to specialist personnel qualiﬁ ed to perform the corresponding task. delivery. The following documents are required in addition for the mainte- −...
Page 30: Replacing The Seal Rings And Ball
Servicing 9.2.1 Replacing the seat rings and ball Check the condition of the ball and seat rings. Remove the seat rings (6 and 7) as described in Chapter 12.2. Check the seat rings as well as all plastic parts for damage and if in doubt replace them.
Page 31: Decommissioning
Decommissioning 10 Decommissioning The work described in this chapter may only be performed by specialist personnel qualiﬁ ed to perform the corresponding task. WARNING Danger of burning due to hot or cold components and pipe! Ball valve components and pipes can become very hot or very cold during operation and cause burns upon contact.
Page 32 Decommissioning EB 28e_EN 10-2 February 2024 edition Subject to technical changes...
Page 33: Removal
Removal 11 Removal 11.2 Disassembling the manual gear box The work described in this chapter may only be performed by See the corresponding documentation. specialist personnel qualiﬁ ed to perform the corresponding task. WARNING Danger of burning due to hot or cold components and pipe! Ball valve components and pipes can become very hot or very cold during operation and cause burns upon contact.
Page 34 Removal EB 28e_EN 11-2 February 2024 edition Subject to technical changes...
Page 35: Repairs
Repairs Place the ball valve on an even and clean work surface so 12 Repairs that the packing space is easy to reach. If the operation of the metering ball valve is no longer compliant Loosen the screws (16) and carefully remove stufﬁ ng box or if it does not work at all, it is defective and must be repaired ﬂ...
Page 36 Repairs Fig. 12-1: Sectional drawing of pig loading ball valve BR 28e EB 28e_EN 12-2 February 2024 edition Subject to technical changes...
Page 37: Sending Devices To Pfeiffer
Repairs Table 12-3: List of parts Item Description Item Description Main body Screw Side body Screw Ball Screw plug Control shaft Screw plug Stufﬁ ng box ﬂ ange Screw Seat ring Trunnion Seat ring Screw Bearing bush Ring Bearing bush Bearing bush V-ring packing Bearing bush...
Page 38 Repairs EB 28e_EN 12-4 February 2024 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 28e_EN 13-1 February 2024 edition Subject to technical changes...
Page 40 Disposal EB 28e_EN 13-2 February 2024 edition Subject to technical changes...
Page 41: 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 manually operated valves, see page 14-2. The printed certiﬁ cates correspond to the status at the time of printing.
Page 42 Certiﬁ cates EB 28e_EN 14-2 February 2024 edition Subject to technical changes...
Page 43: Annex
Annex 15 Annex 15.1.1.3 Packing bush For the assembly of the packing bush, the screw connections are 15.1 Tightening torques, lubricant and tools tightened in a criss-cross pattern with the tightening torques indi- cated below. 15.1.1 Tightening torques Table 15-3: Packing bush tightening torques Nominal size Info Qty.
Page 44: Lubricant
Annex 15.1.3 Tools Tightening torques Tightening [Nm] for sealing units Thread method Suitable tools are required to work on the ball valve. Unsuitable tools can damage the ball valve. 10 ... 16 25 ... 40 10 ... 16 15.2 Spare parts These tightening torques were calculated by the company BASF SE PFEIFFER recommends spare part sets for “Commissioning”...
Page 45 Annex 15.2.1 Spare parts of the pig loading ball valve DN 50 to 80” Fig. 15-1: Exploded drawing of the pig loading ball valve DN 50 ... 80 Table 15-9: Recommend spare parts for the pig loading ball valve Spare parts set Item Description Material...
Page 46 Annex 15.2.2 Spare parts of the pig loading ball valve DN 100 to 200 Fig. 15-2: Exploded drawing of the pig loading ball valve DN 100 ... 200 EB 28e_EN 15-4 February 2024 edition Subject to technical changes...
Page 47 Annex Table 15-10: Recommend spare parts for the pig loading ball valve Spare parts set Item Description Material Commissioning 2-year operation Main body 1.4571 • 1.4408 Side body 1.4571 • 1.4408 Ball 1.4408 • 1.4571 • Control shaft 1.4571 • Stufﬁ...
Page 48: 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 49 EB 28e_EN February 2024 edition Subject to technical changes...
Page 50 EB 28e_EN February 2024 edition Subject to technical changes...
Page 51 EB 28e_EN February 2024 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 28e_EN February 2024 edition Subject to technical changes...

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