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Samson BR 28a Mounting And Operating Instructions
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Samson BR 28a Mounting And Operating Instructions

Metering ball valve
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MOUNTING AND
OPERATING INSTRUCTIONS
EB 28a
Translation of the original manual
Metering ball valve BR 28a • 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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Summary of Contents for Samson BR 28a

  • Page 1 MOUNTING AND OPERATING INSTRUCTIONS EB 28a Translation of the original manual Metering ball valve BR 28a • 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 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 Intended use relevant standards, are capable of evaluating the assigned The BR 28a piggable metering 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 opening 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 28a = Series 28a, 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 Observe the notes in Chapter “ 5 Assembly”. Function and principle of operation Test connection The BR 28a metering ball valves are used for meter medium into The test connection (16) can be used to detect the upper fl ange a piggable piping system.
  • Page 12  − Detailed information is available in the data sheet TB 28a. − The documentation for the special metering ball valves BR 28a that are not described in this chapter can be requested from PFEIFFER. Rotate the control shaft (4) so that the two fl ats are positioned vertical to the working surface.
  • Page 13 Design and principle of operation Fig. 3-2: Sectional drawing of metering ball valve Table 3-2: List of parts Item Description Item Description Main body V-ring packing Side body Disc spring set Ball Disc spring Control shaft Disc spring jacket Stuffi ng box fl ange Sealing Seat ring Screw...
  • Page 14 Design and principle of operation After applying grease to the screws (16) both parts (1 and 2) are screwed together, evenly and in alternating pattern. Info Depending on the nominal size, stud bolts with nuts or screws can be used. The permissible torque for retightening the connection of the body sections can be found in Table 15-1 in Chapter “15.1.1 Tightening torques”.
  • 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 metering 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. 4-3: 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 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 28a_EN November 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 ball valves.
  • Page 20 Installation WARNING DANGER Danger and damage due to use of an electrical actuator! Danger due to exceeding the limits of use! It must be ensured that the actuator in the end positions is Exceeding the limits of use can pose a danger to the user and turned off by the limit switch signal.
  • Page 21 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 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 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 28a_EN November 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 shut-off ball valve is tion of the hand lever indicates the location of the bore in the ready for operation.
  • Page 26 Operation EB 28a_EN November 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. metering 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 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 28a_EN 10-2 November 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 28a_EN 11-2 November 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 metering ball valve is no longer compliant Loosen the screws (15) 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. 12-2: Sectional drawing of metering ball valve BR 28a Table 12-3: List of parts Item Description Item Description Main body V-ring packing Side body Disc spring set Ball Disc spring Control shaft Disc spring jacket Stuffi ng box fl ange...
  • Page 37 Repairs Include the following information for returns: − Manufacturer number − Metering ball valve type − Article number − Nominal size and version of the control valve − Manual valve/automated valve − Medium (designation and consistency) − Medium pressure and temperature −...
  • Page 38 Repairs EB 28a_EN 12-4 November 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 28a_EN 13-1 November 2023 edition Subject to technical changes...
  • Page 40 Disposal EB 28a_EN 13-2 November 2023 edition Subject to technical changes...
  • Page 41 14-3. − Declaration of conformity for completed machinery accord- ing to Machinery Directive 2006/42/EC for the metering ball valve BR 28a, 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, see page 14-5.
  • Page 42 Certifi cates EB 28a_EN 14-2 November 2023 edition Subject to technical changes...
  • Page 43 Certifi cates EB 28a_EN 14-3 November 2023 edition Subject to technical changes...
  • Page 44 Certifi cates EB 28a_EN 14-4 November 2023 edition Subject to technical changes...
  • Page 45 Certifi cates EB 28a_EN 14-5 November 2023 edition Subject to technical changes...
  • Page 46 Certifi cates EB 28a_EN 14-6 November 2023 edition Subject to technical changes...
  • Page 47 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 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 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 Material Spare parts set Item Description ANSI Commissioning 2-year operation Main body 1.4571 1.4408 A182 F316...
  • Page 50 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 28a_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 28a_EN November 2023 edition Subject to technical changes...