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Samson BR 28t Mounting And Operating Instructions
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Samson BR 28t Mounting And Operating Instructions

Ggable, horizontal 3-way ball valve
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MOUNTING AND
OPERATING INSTRUCTIONS
EB 28t
Translation of the original manual
Piggable, horizontal 3-way ball valve BR 28t
DIN and ANSI version
to combine with actuators
for installation in piggable pipes
December 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 28t Translation of the original manual Piggable, horizontal 3-way ball valve BR 28t DIN and ANSI version to combine with actuators for installation in piggable pipes December 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 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 3-way ball valve from the pipe 11-1 11.2 Disassembling the actuator...
  • Page 5 Intended use relevant standards, are capable of evaluating the assigned The BR 28t piggable 3-way ball valve is manually operated in tasks and identifying possible hazards. combination with an actuator for the regulation of the volume fl...
  • Page 6 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 closed position of the ball valve.
  • Page 7 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 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 Remark Manufacturer PFEIFFER Address see Chapter “15.3 Service” Valve type BR (and number value) e.g. BR 28t = Series 28t, 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 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 Function and principle of operation the installation of this protective device is required for the safe The piggable 3-way ball valves of the BR 28t series can be operation of the ball valve in the plant. fl owed through at full fl ow. They are primarily used to meter me- dia in and out of the piping system.
  • Page 12 − Detailed information is available in the data sheet TB 28t. Insert the sealing (7) into the corresponding recesses in the − The documentation for the special ball valves BR 28t that are side bodys (2). not described in this chapter can be requested from PFEIFFER.
  • Page 13 Design and principle of operation Fig. 3-1: Sectional drawing of the 3-way ball valve Table 3-1: List of parts Item Description Item Description Main body Screw Side body Packing bush Ball Bush Control shaft Ring Stuffi ng box fl ange Ring Seat ring Ring...
  • Page 14 Design and principle of operation Place the stuffi ng box fl ange (5) over the control shaft onto Info the packing bush (14). The permissible torque for retightening the side bodys can be Lightly grease the screws (13). found in Table 15-1 in Chapter “15.1.1 Tightening torques”. Adjust the stuffi...
  • Page 15 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 3-way ball valve! specialist personnel qualifi ed to perform the corresponding task. Observe the centre of gravity of the ball valve.
  • Page 16 Shipment and on-site transport Fig. 4-2: Lifting points on the 3-way 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 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 28t_EN December 2023 edition Subject to technical changes...
  • Page 19 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 3-way ball 5.2 Preparing for assembly valves.
  • Page 20 Installation WARNING Danger and damage due to use of an electrical actuator! It must be ensured that the actuator in the end positions is turned off by the limit switch signal. If shut-off takes place in an intermediate position due to the signal of the torque switch, this signal should be used in ad- dition for an error message.
  • Page 21 This is always supplied in the basic position “A-B”. When pushing the ball valve and the required fl ange seals The supplied 3-way ball valve BR 28t must be suitable for the into an already assembled pipe, the distance between the pipe section.
  • Page 22 Installation The ball valve must open and close correctly according to the NOTE control commands. Detected malfunctions must be fi xed be- fore commissioning, see Chapter “8 Malfunction”. Damage to the sealing surfaces and seals or untight fl ange connection due to improper assembly! WARNING Tighten the fl...
  • Page 23 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 28t_EN December 2023 edition Subject to technical changes...
  • Page 25 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 3-way ball valve is tion of the hand lever indicates the location of the bore in the ready for operation.
  • Page 26 Operation EB 28t_EN December 2023 edition Subject to technical changes...
  • Page 27 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 28 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 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 Servicing Measures in the case of a negative Test test result Check the rotary movement of If the actuator- and control shaft are the actuator- and control shaft blocked, remove the blockage. for smooth movement. WARNING! If the actuator- and control shaft are blocked (e.g.
  • Page 31 Decommissioning To decommission the 3-way 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 28t_EN 10-2 December 2023 edition Subject to technical changes...
  • Page 33 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 28t_EN 11-2 December 2023 edition Subject to technical changes...
  • Page 35 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 3-way ball valve is no longer compliant or Loosen the screws (11) and carefully remove the horizontal if it does not work at all, it is defective and must be repaired or side bodys (2).
  • Page 36 Repairs Fig. 12-1: Sectional drawing of the 3-way ball valve Table 12-1: List of parts Item Description Item Description Main body Screw Side body Packing bush Ball Bush Control shaft Ring Stuffi ng box fl ange Ring Seat ring Ring Sealing Bearing bush Bearing bush...
  • Page 37 Repairs Include the following information for returns: − Manufacturer number − 3-way ball valve type − Article number − Nominal size and version of the 3-way valve − Manual valve/automated valve − Medium (designation and consistency) − Medium pressure and temperature −...
  • Page 38 Repairs EB 28t_EN 12-4 December 2023 edition Subject to technical changes...
  • Page 39 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 28t_EN 13-1 December 2023 edition Subject to technical changes...
  • Page 40 Disposal EB 28t_EN 13-2 December 2023 edition Subject to technical changes...
  • Page 41 − Declaration of conformity for completed machinery accord- ing to Machinery Directive 2006/42/EC for the 3-way ball valve BR 28t, see page 14-4. − Declaration of conformity for partly completed machinery ac- cording to Machinery Directive 2006/42/EC for 3-way ball valve BR 28t, see page 14-5.
  • Page 42 Certifi cates EB 28t_EN 14-2 December 2023 edition Subject to technical changes...
  • Page 43 Certifi cates EB 28t_EN 14-3 December 2023 edition Subject to technical changes...
  • Page 44 Certifi cates EB 28t_EN 14-4 December 2023 edition Subject to technical changes...
  • Page 45 Certifi cates EB 28t_EN 14-5 December 2023 edition Subject to technical changes...
  • Page 46 Certifi cates EB 28t_EN 14-6 December 2023 edition Subject to technical changes...
  • Page 47 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 15-1: Packing bush tightening torques Nominal size Info Qty.
  • Page 48 Annex Table 15-3: Sealing unit A 15.2 Spare parts Seal Nominal pressure Description PFEIFFER recommends spare part sets for “Commissioning” and PN 10 to PN 25 Without inner eyelet for “2-year operation”. Flat seal PN 40 With inner eyelet Shaft ring seals PN 40 are covered by this. Flat seals with inner eyelet for PN 10 - 25 are already covered, provid- ing that the required characteristic values are complied with.
  • Page 49 Annex Fig. 15-1: Exploded drawing of the 3-way ball valve EB 28t_EN 15-3 December 2023 edition Subject to technical changes...
  • Page 50 Annex Table 15-6: Recommend spare parts for the 3-way ball valve Spare parts kit Item Description Material Commissioning 2-year operation 1.4571 • 1.4408 Main body 1.4571 • 1.4408 Side body 1.4571 • 1.4408 Ball • Control shaft 1.4462 • 1.4571 • 1.4408 Stuffi...
  • Page 51 EB 28t_EN December 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 28t_EN December 2023 edition Subject to technical changes...