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Samson 251GR Mounting And Operating Instructions
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Samson 251GR Mounting And Operating Instructions

Samson 251GR Mounting And Operating Instructions

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MOUNTING AND OPERATING
INSTRUCTIONS
EB 8003-GR EN
Translation of original instructions
SMS MG-1 Pneumatic Control Valve:
Type 251GR Valve with Type 3271 Actuator
Type 251GR Valve · DIN version
In combination with an actuator, e.g. a Type 3271 or Type 3277 Pneumatic Actuator
Edition May 2025

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Summary of Contents for Samson 251GR

  • Page 1 MOUNTING AND OPERATING INSTRUCTIONS EB 8003-GR EN Translation of original instructions SMS MG-1 Pneumatic Control Valve: Type 251GR Valve with Type 3271 Actuator Type 251GR Valve · DIN version In combination with an actuator, e.g. a Type 3271 or Type 3277 Pneumatic Actuator Edition May 2025...

  • Page 2: Definition Of Signal Words

    These mounting and operating instructions (EB) assist you in mounting and operating the device safely. The instructions are binding for handling SAMSON devices. The images shown in this document are for il- lustration purposes only. The actual product may vary.

  • Page 3: Table Of Contents

    Contents Contents Safety instructions and measures....................5 Notes on possible severe personal injury....................6 Notes on possible personal injury......................7 Notes on possible property damage......................8 Notes on the use of an RFID tag........................ 9 Warnings on the device..........................9 Markings on the device......................... 10 Valve nameplate............................
  • Page 4 Removal............................59 11.1 Removing the valve from the pipeline.....................60 11.2 Removing the actuator from the valve....................60 Repairs..............................61 12.1 Returning devices to SAMSON........................61 Disposal............................62 Certificates............................63 Appendix............................67 15.1 Tightening torques, lubricants and tools....................67 15.1.1 Tightening torques............................67 15.1.2...

  • Page 5: Safety Instructions And Measures

    (see associated actuator documenta- Qualifications of operating personnel tion). When the valve is combined with a SAMSON Type 3271 or Type 3277 Pneumatic Actuator, the The control valve must be mounted, started up, control valve moves to a certain fail-safe position...

  • Page 6: Notes On Possible Severe Personal Injury

    (e.g. differential “Additional Information on Your Inquiry/Order” pressures and temperatures) vary in each individual is added to the SAMSON order documents. This case and are only known to the operator. document includes the SCIP number assigned Responsibilities of operating personnel to the devices concerned.

  • Page 7: Notes On Possible Personal Injury

    WARNING Risk of personal injury due to preloaded springs in pneumatic actuators. Valves in combination with pneumatic actua- tors with preloaded springs are under tension. These control valves with SAMSON Type 3271 or Type 3277 Pneumatic Actuators can be identified EB 8003-GR EN...

  • Page 8: Notes On Possible Property Damage

    Safety instructions and measures by the long bolts protruding from the bottom of the actuator. WARNING _ Before starting any work on the actuator, which Risk of personal injury due to incorrect opera- requires the actuator to be opened, or when the tion, use or installation as a result of informa- actuator stem has become blocked, relieve the tion on the control valve being illegible.

  • Page 9: Notes On The Use Of An Rfid Tag

    RFID tag when it is to be used on valves in- Certain tools are required to work on the valve. stalled in potentially explosive atmospheres. _ Only use tools approved by SAMSON. _ Do not expose the RFID tag to strong electric fields.

  • Page 10: Markings On The Device

    Markings on the device 2 Markings on the device Item Inscription meaning 12 Seat-plug seal: 2.1 Valve nameplate ME: Metal HA: Carbide metal The nameplate shown was up to date at the time of ST: Metal base material with Stellite facing ®...

  • Page 11: Actuator Nameplate

    SAMSON. The ma- terial number enables you to view the device's techni- cal data as configured by SAMSON upon delivery of the device. To view these data, go to our website at: www.samsongroup.com > Products > Electronic...

  • Page 12: Design And Principle Of Operation

    Design and principle of operation 3 Design and principle of operation The Type 251GR Valve is a single-seated globe valve. The Type 251GR Valve is preferably combined with a SAMSON Type 3271 or Type 3277 Pneumatic Actu- ator. A seat and plug with plug stem or a cage and piston with piston stem are installed in the valve.
  • Page 13 Design and principle of operation Fig. 7: Type 251GR Valve · Trim versions · Screwed-in seat and plug Fig. 6: Type 251GR Valve with bellows seal (47) Legend for Fig. 4 to Fig. 6 Valve body Spiral wound gasket Standard bonnet Bellows nut...

  • Page 14: Fail-Safe Positions

    Design and principle of operation (47) Fig. 10: Type 251GR Valve · Trim versions · Screwed-in seat Fig. 13: Type 251GR Valve · Trim versions · Cage and piston and plug with pressure balancing and flow divider ST1 Legend for Fig. 7 to Fig. 13...

  • Page 15: Versions

    It prevents solid particles in the process medium from damaging the control Conformity valve. The Type 251GR Valve bears the CE mark of confor- mity. Bypass and shut-off valves SAMSON recommends installing a shut-off valve both upstream of the strainer and downstream of the control valve and installing a bypass line.

  • Page 16: Noise Emissions

    – T 8310-3 for Type 3271 Actuator with 1400-60 cm² actuator area Technical data Table 1: Technical data for Type 251GR · DIN version Material Cast steel 1.0619 Cast steel 1.7357 Cast stainless steel 1.4408 Nominal size and pressure rating PN 16 to 100: DN 15 to 200 ·...
  • Page 17 Only in combination with suitable body material PN 160 only for version with clamped-in seat or cage trim Only for version with cage trim Materials Table 2: Materials for Type 251GR · DIN version Cast stain- less steel Body of standard version Cast steel 1.0619...

  • Page 18: Dimensional Drawings

    The H2 dimension is the distance from the middle of the flow channel to the bottom of the valve body. The dimension up to the bottom of the flange may differ. It may be lower or higher. Flange standards (see Table 1). PN 63 to 100 only Dimensional drawings Fig. 14: Standard version of Type 251GR Valve Fig. 15: Type 251GR Valve with insulating section EB 8003-GR EN...
  • Page 19 Design and principle of operation Fig. 16: Type 251GR Valve with bellows seal Weights Table 4: Weights in kg for Type 251GR Valve with B1 flanges according to DIN EN 1092-1 Valve Standard version PN 16 PN 25 – PN 40 Valve without actua- PN 63 PN 100...
  • Page 20 Design and principle of operation Valve Version with bellows seal PN 16 – PN 25 – – PN 40 – Valve without actua- PN 63 – PN 100 – PN 160 – – – – – – – – The weights specified apply to a specific standard device configuration. Weights of other valve configurations may differ de- pending on the version (material, trim etc.).

  • Page 21: Shipment And On-Site Transport

    WARNING 2. Check the shipment for transportation damage. Risk of personal injury due to the control valve tip- Report any damage to SAMSON and the for- ping over. warding agent (refer to delivery note). _ Observe the control valve's center of gravity.

  • Page 22: Transporting The Valve

    Shipment and on-site transport A swivel hoist can be screwed into SAMSON actuators with a female thread on the top diaphragm case in place of the eyebolt (see associated actuator documen- tation). In contrast to the lifting eyelet/eyebolt, the swivel hoist is designed for setting a control valve assembly up- right.

  • Page 23: Lifting Instructions

    Shipment and on-site transport Lifting instructions – Use a hook with safety latch to secure the slings from slipping off the hook during lifting and transporting. – Secure slings against slipping. – Make sure the slings can be removed from the device once it has been installed into the pipeline.

  • Page 24: Storing The Valve

    _ Observe the storage instructions. Our after-sales service can provide more detailed stor- _ Avoid longer storage periods. age instructions on request. _ Contact SAMSON in case of different storage condi- tions or longer storage times. Note SAMSON recommends to regularly check the control valve and the prevailing storage conditions during long storage periods.

  • Page 25: Installation

    The inlet and outlet lengths (see Table 5) vary de- pending on several variables and process condi- tions and are intended as recommendations. Con- tact SAMSON if the lengths are significantly shorter than the recommended lengths. To ensure that the control valve functions properly,...

  • Page 26: Mounting Position

    Vent plug low temperatures below -10 °C Vent plugs are screwed into the exhaust air ports of _ Contact SAMSON if the mounting position is not pneumatic and electropneumatic devices. They en- as specified above. sure that any exhaust air that forms can be vented...

  • Page 27: Preparation For Installation

    _ Observe tightening torques. NOTICE Risk of valve damage due to the use of unsuitable tools. Certain tools are required to work on the valve. _ Only use tools approved by SAMSON.   5.3.1 Mounting the external anti-rota- ...
  • Page 28 Installation the hand-operated actuator (handwheel) to mount NOTICE the anti-rotation fixture ( EB 8312-X). Impaired functioning due to incorrectly applied Standard version for Series SMS Valves in nomi- lubricant. nal sizes DN 150/NPS 6 to DN 300/NPS 12 _ Do not apply any lubricant to the threads of the clamps (301) or plug/piston stem.
  • Page 29 Installation Fig. 23: Overview of anti-rotation fixture assembly in the standard version Stem 304 Washers 114 Lubricant Gleitmo 1763 V 309 Sliding washers 301 Clamps Plug stem Fig. 22: Overview of yoke assembly with travel indicator 303 Screws scale in the standard version Special version for Series SMS Valves in nominal Yoke Castellated nut...
  • Page 30 Installation 4. Place the yoke (3) on the bonnet in such a way – There is a nominal clearance of 0.5 to 1 mm that the two holes on the top of the bonnet are between the sliding washers and their con- aligned with the open sides of the yoke (see tact surface on the yoke on each side (see Fig.
  • Page 31 Installation Fig. 25: Overview of anti-rotation fixture assembly in the special version Stem 304 Washers 114 Lubricant Gleitmo 1763 V 309 Sliding washers 301 Clamps Plug stem 303 Screws Same alignment as a 90° to a Fig. 26: Alignment of bonnet on the valve body and alignment of yoke on the bonnet Pipeline axis Yoke...
  • Page 32 Installation Table 8: Mounting dimensions for Types 3271 and 3277 Pneumatic Actuators · See Fig. 27 for dimensional drawing Actu- Trav- Actuator Nominal size ator preloading Dimension when the valve is closed [mm] [cm²] [mm] [%] [mm] DN 50 to 100/NPS 2 to 4 · Special version 350v2 3.75 355v2...

  • Page 33: Mounting The Actuator Onto The Valve

    Valves in combination with pneumatic actuators with preloaded springs are under tension. These control valves with SAMSON Type 3271 or Type 3277 Pneu- matic Actuators can be identified by the long bolts pro- truding from the bottom of the actuator.

  • Page 34: Mounting The Actuator

    Installation _ Before mounting the actuator, check the hole Depending on the version, SAMSON control valves pattern of the perforated plug and determine are either delivered with the actuator already which hole is the closest to the seal facing. This...

  • Page 35: Installing The Valve Into The Pipeline

    Installation 5.4 Installing the valve into the Version with welding ends pipeline 1. Close the shut-off valves in the pipeline at the inlet and outlet of the plant section while the valve is being installed. NOTICE 2. Prepare the relevant section of the pipeline for Risk of valve damage due to work being carried out installing the valve.

  • Page 36: Leak Test

    Additionally, a loud noise preloaded springs are under tension. These control may briefly occur through the sudden venting of the valves with SAMSON Type 3271 or Type 3277 Pneu- pneumatic actuator or pneumatic valve accessories matic Actuators can be identified by the long bolts pro- not fitted with noise-reducing elements.
  • Page 37 Installation Adjusting the packing The sealing elements of the adjustable packing are compressed between the valve body and plug stem by applying a specified tightening torque. If the packing leaks, the threaded bushing or pack- ing flange can be repeatedly tightened further by the specified tightening torque during the valve's service life until the sealing elements must be re- placed.

  • Page 38: Travel Motion

    Installation Our after-sales service can support you to plan and perform a pressure test for your plant. During the pressure test, make sure the following conditions are met: – Retract the plug/piston to open the valve. – Observe the maximum permissible pressure for both the valve and plant.

  • Page 39: Start-Up

    Start-up 6 Start-up WARNING The work described in this chapter is to be per- Crush hazard arising from moving parts. formed only by personnel appropriately qualified to The control valve contains moving parts (actuator carry out such tasks. stem and plug/piston stem), which can injure hands or fingers if inserted into the valve.
  • Page 40 Start-up Start-up/putting the device back into operation 1. Allow the valve to cool down or warm up to reach ambient temperature before start-up when the ambient temperature and process medium temperature differ greatly or the medi- um properties require such a measure. 2.

  • Page 41: Operation

    Operation 7 Operation WARNING Immediately after completing start-up or putting Crush hazard arising from moving parts. the valve back into operation, the valve is ready for The control valve contains moving parts (actuator use. stem and plug/piston stem), which can injure hands or fingers if inserted into the valve.

  • Page 42: Malfunctions

    Malfunctions 8 Malfunctions Read hazard statements, warnings and caution notes in Chapter 1. 8.1 Troubleshooting Malfunction Possible reasons Recommended action Actuator and plug/piston Actuator is blocked. Put the control valve out of operation (see Chapter 10) and re- stem does not move on move the blockage.

  • Page 43: Emergency Action

    Malfunctions Note Contact SAMSON's After-sales Service for malfunctions not listed in the table. 8.2 Emergency action Plant operators are responsible for emergency ac- tion to be taken in the plant. In the event of a valve malfunction: 1. Close the shut-off valves upstream and down- stream of the control valve to stop the process medium from flowing through the valve.

  • Page 44: Servicing And Conversion

    Servicing and conversion 9 Servicing and conversion In the event of a potential risk: _ Allow components and pipelines to cool down The work described in this chapter is to be per- or warm up to the ambient temperature. formed only by personnel appropriately qualified to _ Wear protective clothing and safety gloves.

  • Page 45: Periodic Testing

    _ Before starting any work on the actuator, which re- quires the actuator to be opened, or when the ac- Note tuator stem has become blocked, relieve the com- The control valve was checked by SAMSON before de- pression from the preloaded springs (see associat- livery. ed actuator documentation).
  • Page 46 Our after-sales service can support you in drawing up an inspection and test plan for your plant. SAMSON recommends the following inspections and tests: Inspection and testing Recommended action to be taken in the event of a negative re-...
  • Page 47 (e.g. spring com- pression). See associated actuator documentation. SAMSON recommends the use of positioners with integrated diag- nostic firmware for control valves used for on/off service. The par- tial stroke test included in this software helps prevent a shut-off valve normally in its end position from seizing up or getting jammed.
  • Page 48 Servicing and conversion Fig. 33: Possible points of leakage on the control valve: Version with standard bonnet (left) and version with bellows seal (right), which also applies to versions with insulating section or intermediate piece. External leakage Seat/body and plug/seat Connection to the pipeline Seat leakage (static sealing)

  • Page 49: Preparation For Servicing Or Conversion Work

    Servicing and conversion 9.2 Preparation for servicing or conver- sion work SAMSON recommends removing the valve from the pipeline before performing any service work (see Chap- WARNING ter 11). Risk of personal injury due to incorrect removal of the anti-rotation fixture under tension.

  • Page 50: Replacing Gaskets In Versions With Standard Bonnet Or Insulating Section

    Servicing and conversion 3. Pull the valve bonnet (2/21) including yoke (60) upward off the plug stem (36) and lift it off the NOTICE body (1). If necessary, slightly press the plug Risk of control valve damage due to incorrect ser- stem (36) downward.

  • Page 51: Replacing The Packing In Versions With Standard Bonnet Or Insulating Section

    Version with perforated plug: Align the plug (5), making sure that the hole of the plug that SAMSON recommends using new packing parts. releases the flow first faces toward the valve outlet. c) Version with cage and piston See Chapter 5.3.2 in all cases.
  • Page 52 Servicing and conversion 1. Gradually unthread the two packing nuts (163) at the hex head in a crisscross pattern. Same alignment as a 2. Lift the two packing nuts (including disk springs when packing flange is loaded by external spring elements) as well as the packing flange (162) upward over the studs (164) off the valve bonnet (2/21).

  • Page 53: Replacing The Trim In Versions With Standard Bonnet Or Insulating Section

    (162) upward over the studs (164) off the valve bonnet (2/21). c) Pull out the packing follower (8). SAMSON recommends using new packing parts and 2. Undo the body nuts (14) gradually in a criss- gaskets when replacing the trim.
  • Page 54 Servicing and conversion stem (36) to ensure that the trim remains in the 8. Remove the cage (424) from the body (1). Use body (1). special tool for large nominal sizes. 4. Pull all the packing parts out of the packing 9.
  • Page 55 Servicing and conversion e) Installing the (screwed-in) seat and plug f) Installing the cage and piston (≤NPS 6, ≤Class 600) NOTICE 1. Clean the inside of the valve body (seating sur- faces of the gaskets) and check it to ensure that Risk of valve damage due to poor flow conditions. it is free of damage.

  • Page 56: Replacing The Plug/Piston On The Plug/Piston Stem

    To prevent the plug/piston from becom- ing unintentionally detached from the plug/piston Contact your nearest SAMSON subsidiary or stem, the connection is additionally secured by a SAMSON's After-sales Service for information on tangentially inserted pin (see Fig. 37). To replace the spare parts, lubricants and tools.

  • Page 57: Decommissioning

    Decommissioning 10 Decommissioning WARNING The work described in this chapter is to be per- Risk of hearing loss or deafness due to loud noise. formed only by personnel appropriately qualified to Noise emission (e.g. cavitation or flashing) may occur carry out such tasks. during operation caused by the process medium and the operating conditions.
  • Page 58 Decommissioning WARNING Risk of personal injury due to residual process medium in the valve. While working on the valve, residual medium can flow out of the valve and, depending on its properties, cause personal injury, e.g. (chemical) burns. _ Follow the standard operating procedures provid- ed by the plant operator.

  • Page 59: Removal

    Valves in combination with pneumatic actuators with ed by the plant operator. preloaded springs are under tension. These control valves with SAMSON Type 3271 or Type 3277 Pneu- In the event of a potential risk: matic Actuators can be identified by the long bolts pro- _ Allow components and pipelines to cool down truding from the bottom of the actuator.

  • Page 60: Removing The Valve From The Pipeline

    Removal 11.1 Removing the valve from the pipeline Version with flanges 1. Support the control valve to hold it in place when separated from the pipeline (see Chap- ter 4). 2. Unbolt the flanged joint. 3. Remove the valve from the pipeline (see Chap- ter 4).

  • Page 61: Repairs

    _ Do not perform any repair work on your own. _ Contact SAMSON's After-sales Service for service and repair work. 12.1 Returning devices to SAMSON Defective devices can be returned to SAMSON for repair. Proceed as follows to return devices: 1. Exceptions apply concerning some special device models www.samsongroup.com >...

  • Page 62: Disposal

    Simply e-mail us at aftersalesservice@samsongroup.com giving details of your company address. On request, SAMSON can appoint a service provider to dismantle and recycle the product as part of a distrib- utor take-back scheme. _ Observe local, national and international refuse regulations.

  • Page 63: Certificates

    – Country of origin: Germany – Declaration of conformity in compliance with Machinery Directive 2006/42/EC for Types 251GR-1 and 251GR-7 Control Valves – Declaration of incorporation in compliance with Machinery Directive 2006/42/EC for Type 251GR Valve with other actuators other than the Type 3271 or Type 3277 Actuator...
  • Page 64 Manufacturer: SAMSON AKTIENGESELLSCHAFT, Weismüllerstrasse 3, 60314 Frankfurt am Main, Germany Frankfurt am Main, February 17, 2025 Dr. Andreas Widl Sebastian Krause Chief Executive Officer (CEO) Vice President Product Development Revision 13 Classification: Public · SAMSON AKTIENGESELLSCHAFT · Weismüllerstrasse 3 · 60314 Frankfurt am Main, Germany Page 1 of 1...
  • Page 65 Annex II, section 1.A. of the Directive 2006/42/EC For the following products: Types 251GR-1/-7 Pneumatic Control Valves consisting of the Type 251GR Valve and Type 3271/Type 3277 Pneumatic Actuator We hereby declare that the machinery mentioned above complies with all applicable requirements stipulated in Machinery Directive 2006/42/EC.
  • Page 66 SAMSON AG, Weismüllerstraße 3, 60314 Frankfurt am Main, Germany Frankfurt am Main, 7. November 2024 Stephan Giesen Sebastian Krause Director Product Management Vice President Product Development Revision no. 00 Classification: Public · SAMSON AKTIENGESELLSCHAFT · Weismüllerstraße 3 · 60314 Frankfurt am Main, Germany Page 1 of 1...

  • Page 67: Appendix

    Appendix 15 Appendix Number of Tightening sequence of bolts numbered se- bolts quentially in the clockwise direction 15.1 Tightening torques, lubricants and 1, 13, 5, 17, 9, 3, 15, 7, 11, 2, 14, 6, 18, 10, 4, 16, tools 8, 12 1, 13, 5, 17, 9, 3, 15, 7, 19, 11, 2, 14, 6, 18, 10, 4, 15.1.1 Tightening torques 16, 8, 20, 12...

  • Page 68: Lubricants

    Appendix 15.1.2 Lubricants Tightening torque for body nut (14) Nomi- nal size Pressure rating PN … WARNING Exposure to hazardous substances poses a serious – risk to health. 1050 1180 – Certain lubricants and cleaning agents are classified 1150 – as hazardous substances.

  • Page 69: Tools

    Depending on the valve model and ver- sion, special tools may be required for certain pro- cedures. The required special tools can be purchased from SAMSON. _ Contact our after-sales service. EB 8003-GR EN...

  • Page 70: Spare Parts

    Appendix 15.2 Spare parts Packing nuts for packing flange (including disk springs when packing flange is loaded Valve body by external spring elements) Standard bonnet Stud Seat Spiral wound gasket Plug/piston Retaining ring for seat Anti-rotation fixture (bellows seal) Bushing 1)2) Threaded bushing/packing follower Lubricants...
  • Page 71 Appendix Packing with packing flange (live-loaded by external spring elements) Centrally fastened packing (live-loaded or adjustable, depending on the packing set) Packing with packing flange (adjustable without external spring elements) Standard bonnet Version with insulating section Valves with bellows seal Screwed-in seat and plug with pressure balancing Screwed-in seat and plug with flow divider Piston and cage...

  • Page 72: After-Sales Service

    Addresses of SAMSON AG and its subsidiaries The addresses of SAMSON AG, its subsidiaries, rep- resentatives and service facilities worldwide can be found in all SAMSON product catalogs or on our website ( www.samsongroup.com). Required specifications Please submit the following details: –...
  • Page 76 EB 8003-GR EN SAMSON AKTIENGESELLSCHAFT Weismüllerstraße 3 · 60314 Frankfurt am Main, Germany Phone: +49 69 4009-0 · Fax: +49 69 4009-1507 samson@samsongroup.com · www.samsongroup.com...