Mounting and Operating Instructions EB 8115 EN · EB 8115 EN 5 Safety instructions and measures 1...

Mounting and Operating Instructions

EB 8115 EN

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Edition May 2018

Type 3321CT Valve (Clean Tech)For combining with actuators, e.g. with Type 3379 Pneumatic Actuator

DIN version

2 EB 8115 EN

Note on these mounting and operating instructions

These mounting and operating instructions assist you in mounting and operating the device safely. The instructions are binding for handling SAMSON devices.

Î For the safe and proper use of these instructions, read them carefully and keep them for later reference.

Î If you have any questions about these instructions, contact SAMSON‘s After-sales Service Department ([email protected]).

The mounting and operating instructions for the devices are included in the scope of delivery. The latest documentation is available on our website at www.samson.de > Service & Support > Downloads > Documentation.

Definition of signal words

Hazardous situations which, if not avoided, will result in death or serious injury

Hazardous situations which, if not avoided, could result in death or serious injury

Property damage message or malfunction

Additional information

Recommended action

DANGER!

WARNING!

NOTICE!

Note

Tip

Contents

EB 8115 EN 3

1 Safety instructions and measures ...................................................................51.1 Notes on possible severe personal injury .........................................................81.2 Notes on possible personal injury ...................................................................81.3 Notes on possible property damage ................................................................92 Markings on the device ...............................................................................101.4 Valve labeling ..............................................................................................101.5 Actuator nameplate ......................................................................................113 Design and principle of operation ................................................................121.1 Fail-safe positions ........................................................................................121.1 Technical data .............................................................................................144 Measures for preparation ............................................................................161.1 Unpacking ..................................................................................................161.2 Transporting and lifting ................................................................................161.2.1 Transporting ................................................................................................171.2.2 Lifting ..........................................................................................................171.1 Storage .......................................................................................................181.2 Preparation for installation ............................................................................195 Mounting and start-up .................................................................................201.1 Mounting the actuator onto the valve .............................................................201.2 Installing the valve into the pipeline ...............................................................221.2.1 Checking the installation conditions ...............................................................221.2.2 Additional fittings .........................................................................................241.2.3 Installing the control valve .............................................................................241.3 Preparing for operation ................................................................................241.4 Quick check ................................................................................................256 Operation ...................................................................................................267 Servicing.....................................................................................................271.1 Replacing the gasket ....................................................................................281.2 Replacing the packing ..................................................................................301.3 Replacing the seat and plug ..........................................................................311.4 Preparation for return shipment .....................................................................32

4 EB 8115 EN

Contents

1.5 Ordering spare parts and operating supplies .................................................338 Malfunctions ...............................................................................................341.1 Troubleshooting ...........................................................................................341.1 Emergency action ........................................................................................359 Decommissioning and disassembly ..............................................................361.1 Decommissioning .........................................................................................361.2 Removing the valve from the pipeline .............................................................361.3 Disposal ......................................................................................................3610 Appendix ....................................................................................................371.1 After-sales service ........................................................................................371.2 Certificates ..................................................................................................371.1 Spare parts .................................................................................................39

EB 8115 EN 5

Safety instructions and measures

1 Safety instructions and measuresIntended useThe SAMSON Type 3321CT Globe Valve in combination with an actuator (e.g. Type 3379 Pneumatic Actuator) is designed to regulate the flow rate, pressure or temperature of liquids, gases or vapors.The valve with its actuator is designed to operate under exactly defined conditions (e.g. oper-ating pressure, process medium, temperature). Therefore, operators must ensure that the con-trol valve is only used in operating conditions that meet the specifications used for sizing the valve at the ordering stage. In case operators intend to use the control valve in other applica-tions or conditions than specified, contact SAMSON.SAMSON does not assume any liability for damage resulting from the failure to use the de-vice for its intended purpose or for damage caused by external forces or any other external factors.

Î Refer to the technical data and nameplate for limits and fields of application as well as possible uses.

Reasonably foreseeable misuseThe control valve is not suitable for the following applications: − Use outside the limits defined during sizing and by the technical data − Use outside the limits defined by the valve accessories mounted on the control valve

Furthermore, the following activities do not comply with the intended use: − Use of non-original spare parts − Performing service and repair work not described in these instructions

Qualifications of operating personnelThe control valve must be mounted, started up, serviced and repaired by fully trained and qualified personnel only; the accepted industry codes and practices are to be observed. Ac-cording to these mounting and operating instructions, trained personnel refers to individuals who are able to judge the work they are assigned to and recognize possible hazards due to their specialized training, their knowledge and experience as well as their knowledge of the applicable standards.

6 EB 8115 EN


Personal protective equipmentWe recommend checking the hazards posed by the process medium being used (e.g. u GESTIS (CLP) hazardous substance database).

Î Provide protective equipment (e.g. safety gloves, eye protection) appropriate for the pro-cess medium used.

Î Wear hearing protection when working near the valve. Î Check with the plant operator for details on further protective equipment.

Revisions and other modificationsRevisions, conversions or other modifications of the product are not authorized by SAMSON. They are performed at the user's own risk and may lead to safety hazards, for example. Fur-thermore, the product may no longer meet the requirements for its intended use.

Safety devicesUpon supply air or control signal failure, the valve moves to its fail-safe position (see sec-tion 3.1). The fail-safe action of the actuator is the same as its direction of action and is spec-ified on the nameplate of SAMSON actuators (see actuator documentation).

Warning against residual hazardsTo avoid personal injury or property damage, plant operators and operating personnel must prevent hazards that could be caused in the control valve by the process medium, the operat-ing pressure, the signal pressure or by moving parts by taking appropriate precautions. They must observe all hazard statements, warning and caution notes in these mounting and oper-ating instructions, especially for installation, start-up and service work.We also recommend checking the hazards posed by the process medium being used (e.g. u GESTIS (CLP) hazardous substance database).

Î Observe safety measures for handling the device.

Responsibilities of the operatorThe operator is responsible for proper operation and compliance with the safety regulations. Operators are obliged to provide these mounting and operating instructions as well as the referenced documents to the operating personnel and to instruct them in proper operation. Furthermore, the operator must ensure that operating personnel or third persons are not ex-posed to any danger.

http://www.dguv.de/ifa/gestis/gestis-stoffdatenbank/index-2.jsp

http://www.dguv.de/ifa/gestis/gestis-stoffdatenbank/index-2.jsp

EB 8115 EN 7


Responsibilities of operating personnelOperating personnel must read and understand these mounting and operating instructions as well as the referenced documents and observe the specified hazard statements, warnings and caution notes. Furthermore, the operating personnel must be familiar with the applicable health, safety and accident prevention regulations and comply with them.

Referenced standards and regulationsThe control valves comply with the requirements of the European Pressure Equipment Direc-tive 2014/68/EU. Valves with a CE marking have an EU declaration of conformity, which includes information about the applied conformity assessment procedure. This EU declaration of conformity is included in the Appendix of these instructions (see section 10.2).According to the ignition risk assessment performed in accordance with EN 13463-1:2009, section 5.2, the non-electrical control valves do not have their own potential ignition source even in the rare incident of an operating fault. As a result, they do not fall within the scope of Directive 2014/34/EU.

Î For connection to the equipotential bonding system, observe the requirements specified in section 6.4 of EN 60079-14 (VDE 0165 Part 1).

Referenced documentationThe following documents apply in addition to these mounting and operating instructions: − Mounting and operating instructions for the mounted actuator, e.g. u EB 8315 for

Type 3379 Pneumatic Actuator − Mounting and operating instructions for mounted valve accessories (positioner, solenoid

valve, etc.) − u AB 0100 for tools, tightening torques and lubricant

https://www.samson.de/document/e83150en.pdf

http://www.samson.de/pdf_en/e01000en.pdf

8 EB 8115 EN


1.1 Notes on possible severe personal injury

DANGER!

Risk of bursting in pressure equipment.Valves and pipelines are pressure equipment. Improper opening can lead to valve components bursting.

Î Before starting any work on the valve, depressurize all plant sections concerned as well as the valve.

Î Drain the process medium from all the plant sections concerned as well as the valve.

Î Wear personal protective equipment.

1.2 Notes on possible personal injury

WARNING!

Crush hazard arising from moving parts.The control valve contains moving parts (actuator and plug stems), which can injure hands or fingers if inserted into the valve.

Î Do not insert hands or fingers into the yoke while the valve is in operation. Î While working on the control valve, disconnect and lock the pneumatic air supply.

Risk of personal injury when the pneumatic actuator vents.While the valve is operating, the actuator may vent during closed-loop control or when the valve opens or closes.

Î Install the control valve in such a way that the actuator does not vent at eye level. Î Use suitable silencers and vent plugs. Î Wear eye protection when working in close proximity to the control valve.

Risk of personal injury due to residual process medium in the valve.While working on the valve, residual process medium can escape and, depending on its properties, may lead to personal injury, e.g. (chemical) burns.

Î If possible, drain the process medium from all the plant sections concerned and the valve.

Î Wear protective clothing, safety gloves, and eyewear.

EB 8115 EN 9


WARNING!

Risk of burn injuries due to hot or cold components and pipelines.Depending on the process medium, valve components and pipelines may get very hot or cold and cause burn injuries.

Î Allow components and pipelines to cool down or heat up. Î Wear protective clothing and safety gloves.

1.3 Notes on possible property damage

NOTICE!

Risk of valve damage due to contamination (e.g. solid particles) in the pipeline.The plant operator is responsible for cleaning the pipelines in the plant.

Î Flush the pipelines before start-up. Î Observe the maximum permissible pressure for valve and plant.

Risk of valve damage due to unsuitable medium properties.The valve is designed for a process medium with defined properties.

Î Only use the process medium specified for sizing.

Risk of leakage and valve damage due to excessively high or low tightening torques.Observe the specified torques on tightening control valve components. Excessively tight-ened torques lead to parts wearing out quicker. Parts that are too loose may cause leak-age.

Î Observe the specified tightening torques (u AB 0100).

Risk of valve damage due to the use of unsuitable tools.Certain tools are required to work on the valve.

Î Only use tools approved by SAMSON (u AB 0100).

Risk of valve damage due to the use of unsuitable lubricants.The lubricants to be used depend on the valve material. Unsuitable lubricants may cor-rode and damage the valve surface.

Î Only use lubricants approved by SAMSON (u AB 0100).




10 EB 8115 EN

Markings on the device

NOTICE!

Risk of contamination of the process medium through the use of unsuitable lubricant and/or contaminated tools and components.

Î Keep the valve and the tools used free from solvents and grease. Î Make sure that only suitable lubricants are used (u AB 0100).

2 Markings on the device

2.1 Valve labeling6 71214 15 16 171…5 9

20

1…5 PED (Pressure Equipment Directive), "Art. 4, Abs. 3"ID of the notified body, fluid group and category

6 Type designation7 Device index9 Year of manufacture

12 Production number14 Flow coefficient: KVS

15 Characteristic: % (equal percentage)16 Seat-plug seal:

ME: metalPK: soft seal with PEEK

17 Seat code (trim material): 00 (1.4404)20 Country of origin

The details on the device version are lasered onto the valve bonnet (Fig. 1). No nameplate is used.


EB 8115 EN 11

Markings on the device

Valve labeling

Fig. 1: Valve labeling

2.2 Actuator nameplateSee associated actuator documentation.

12 EB 8115 EN

Design and principle of operation

3 Design and principle of oper-ation

The single-seated Type 3321CT Globe Valve is preferably combined with a SAMSON Type 3379 Pneumatic Actuator.The seat (2) and plug with plug stem (3) are installed in the body (1). The plug stem has a thread to screw it onto the actuator stem and is sealed by the spring-loaded packing (8).The process medium flows through the valve in the direction indicated by the arrow in the flow-to-open direction. The plug position de-termines the cross-sectional area between the seat and plug.

The position of the plug is changed by the control signal acting on the actuator.

3.1 Fail-safe positionsDepending on how the compression springs are arranged in the pneumatic actuator, the valve has two fail-safe positions that become effective when the supply air fails: − Fail-close: the valve is closed upon air

supply failure. − Fail-open: the valve is opened upon air

supply failure.

1 Body2 Seat3 Plug4 Guide bushing7 Valve bonnet8 V-ring packing10 Hexagon screw13 Body gasket14 Flange

Fig. 2: Type 3321CT Valve, DN 15 to 25

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EB 8115 EN 13



2

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Fig. 3: Type 3321CT Valve, DN 32 to 50

14 EB 8115 EN


3.2 Technical dataThe nameplates on the valve and actuator provide information on the control valve ver-sion. See section 2.1 and the actuator docu-mentation.

More information is available in Data Sheet u T 8115.

Noise emissionSAMSON is unable to make general state-ments about noise emission as it depends on the valve version, plant facilities and process medium.

Risk of hearing loss or deafness due to loud noise.Wear hearing protection when working near the valve.

Dimensions and weightsThe dimensions and weights are listed in Ta-ble 2.

Refer to the following documents for more dimensions and weights:u EB 8315 for Type 3379 Pneumatic Actua-toru T 8395 for Type 3724 Electropneumatic Positioner

Note

WARNING!

Note

Table 1: Technical data

Valve size DN 15 to 50Pressure rating PN 16 and 40Type of connection Flanges with raised face Form B1 according to EN 1092-1Seat-plug seal Metal or soft sealCharacteristic Equal percentageRangeability 50 :1Permissible medium temperature

Standard version 0 to 220 °CLeakage class according to IEC 60534-4 or ANSI/FCI 70-2

Metal seal IVSoft seal VI

Compliance

http://www.samson.de/pdf_en/t81150en.pdf


https://www.samson.de/document/t83950en.pdf

EB 8115 EN 15


Table 2: Dimensions and weights

DN 15 20 25 32 40 50

L 130 150 160 180 200 230

H1 102 114

H2 40 72

Weight 5 6 7 11 12 16

L

H1H2

Type 3321CT

16 EB 8115 EN

Measures for preparation

4 Measures for preparationAfter receiving the shipment, proceed as fol-lows:1. Check the scope of delivery. Compare

the shipment received with the delivery note.

2. Check the shipment for transportation damage. Report any damage to SAM-SON and the forwarding agent (refer to delivery note).

4.1 Unpacking

Do not remove the packaging until immedi-ately before installing the valve into the pipe-line.

Proceed as follows to lift and install the valve:1. Remove the packaging from the valve.2. Dispose of the packaging in accordance

with the valid regulations.

Risk of valve damage due to foreign parti-cles entering the valve.The protective caps fitted on the valve's inlet and outlet prevent foreign particles from en-tering the valve and damaging it.Do not remove the protective caps until im-mediately before installing the valve into the pipeline.

4.2 Transporting and lifting

Hazard due to suspended loads falling.Stay clear of suspended or moving loads.

Risk of lifting equipment tipping and risk of damage to lifting accessories due to exceed-ing the rated lifting capacity. − Only use approved lifting equipment and accessories whose minimum lifting capacity is higher than the weight of the valve (including actuator, if applicable). − Refer to section 3.2 or Data Sheet u T 8115 for weights.

Risk of personal injury due to the control valve tipping. − Observe the valve's center of gravity. − Secure the valve against tipping over or turning.

Note

NOTICE!

DANGER!

WARNING!

WARNING!

http://www.samson.de/pdf_en/t81150en.pdf

EB 8115 EN 17


Risk of valve damage due to incorrectly at-tached slings. − When lifting the control valve, make sure that the slings attached to the valve body bear the entire load. − Do not attach load-bearing slings to the actuator, handwheel or any other parts. − Observe lifting instructions (see sec-tion 4.2.2).

SAMSON's After-sales Service department can provide more detailed transport and lift-ing instructions on request.

4.2.1 TransportingThe control valve can be transported using lifting equipment (e.g. crane or forklift).

Î Leave the control valve in its transport container or on the pallet to transport it.

Î Observe the transport instructions.

Transport instructions − Protect the control valve against external

influences (e.g. impact). − Do not damage the corrosion protection

(paint, surface coatings). Repair any damage immediately.

− Protect the control valve against moisture and dirt.

− The permissible transportation tempera-ture of standard control valves is –20 to +65 °C.

Contact SAMSON's After-sales Service de-partment for the transportation temperatures of other valve versions.

4.2.2 LiftingTo install a large valve into the pipeline, use lifting equipment (e.g. crane or forklift) to lift it.

Lifting instructions − Secure slings against slipping. − Make sure the slings can be removed

from the valve once it has been installed into the pipeline.

− Prevent the control valve from tilting or tipping.

− Do not leave loads suspended when in-terrupting work for longer periods of time.

− Make sure that the axis of the pipeline is always horizontal during lifting and the axis of the plug stem is always vertical.

NOTICE!

Tip

Note

18 EB 8115 EN


Fig. 4: Lifting points on the control valve

Lifting the control valve1. Attach one sling to each flange of the

body and to the rigging equipment (e.g. hook) of the crane or forklift (see Fig. 4).

2. Carefully guide two slings around the ac-tuator. Secure the slings against slipping by using a connector.

3. Carefully lift the control valve. Check whether the lifting equipment and acces-sories can bear the weight.

4. Move the control valve at an even pace to the site of installation.

5. Install the valve into the pipeline (see sec-tion 5.2.3).

6. After installation in the pipeline, check whether the flanges are bolted tight and the valve in the pipeline holds.

7. Remove slings.

We recommend using a hook with safety latch (see Fig. 4). The safety latch prevents the slings from slipping during lifting and transporting.

4.3 Storage

Risk of valve damage due to improper stor-age. − Observe storage instructions. − Avoid long storage times. − Contact SAMSON in case of different stor-age conditions or long storage periods.

We recommend regularly checking the con-trol valve and the prevailing storage condi-tions during long storage periods.

Storage instructions − Protect the control valve against external

influences (e.g. impact). − Do not damage the corrosion protection

(paint, surface coatings). Repair any damage immediately.

− Protect the control valve against moisture and dirt. Store it at a relative humidity of less than 75 %. In damp spaces, prevent condensation. If necessary, use a drying agent or heating.

Tip

NOTICE!

Note

EB 8115 EN 19


− Make sure that the ambient air is free of acids or other corrosive media.

− The permissible storage temperature of standard control valves is –20 to +65 °C.

Contact SAMSON's After-sales Service de-partment for the storage temperatures of oth-er valve versions.

− Do not place any objects on the control valve.

SAMSON's After-sales Service department can provide more detailed storage instruc-tions on request.

4.4 Preparation for installationProceed as follows:

Î Flush the pipelines.

The plant operator is responsible for clean-ing the pipelines in the plant.

Î Check the valve to make sure it is clean.

Risk of contamination of the process medium through the use of unsuitable lubricant and/or contaminated tools and components. − Keep the valve and the tools used free from solvents and grease.

− Make sure that only suitable lubricants are used.

Î Check the valve for damage. Î Check to make sure that the type desig-nation, valve size, material, pressure rat-ing and temperature range of the valve match the plant conditions (size and pressure rating of the pipeline, medium temperature, etc.).

Î Check any mounted pressure gauges to make sure they function.

Î When the valve and actuator are al-ready assembled, check the tightening torques of the bolted joints (u AB 0100). Components may loosen during trans-port.

Note

Tip

Note

NOTICE!


20 EB 8115 EN

Mounting and start-up

5 Mounting and start-upSAMSON valves are delivered ready for use. In special cases, the valve and actuator are delivered separately and must be assem-bled on site. Proceed as follows to mount and start up the valve.

Risk of valve damage due to excessively high or low tightening torques.Observe the specified torques on tightening control valve components. Excessively tight-ened torques lead to parts wearing out quicker. Parts that are too loose may cause leakage.Observe the specified tightening torques (u AB 0100).

Risk of valve damage due to the use of un-suitable tools.Only use tools approved by SAMSON (u AB 0100).

Risk of contamination of the process medium through the use of unsuitable lubricant and/or contaminated tools and components. − Keep the valve and the tools used free from solvents and grease. − Make sure that only suitable lubricants are used.

5.1 Mounting the actuator onto the valve

1. Make sure that the valve is completely open (the plug stem is completely retract-ed).Version with "actuator stem extends" fail-safe action: apply a signal pressure that corresponds to the upper bench range value to the connection on the bot-tom diaphragm chamber.Version with "actuator stem retracts" fail-safe action: make sure that no signal pressure is applied to the actuator.

2. Undo the hexagon screws (10) on the valve bonnet (7).

3. Lift the flange (14), valve bonnet (7) to-gether with the plug and plug stem (3) off the body (1).

4. Apply a suitable thread-locking fluid to the female thread of the actuator stem.

5. Screw the plug stem (3) into the actuator stem. Observe tightening torques.

6. Apply a suitable lubricant to the thread of the valve bonnet (7).

7. Screw the valve bonnet (7) into the actu-ator base until it reaches the metal stop. Observe tightening torques.

8. Carefully place the actuator, valve bon-net (7), flange (14) and plug with plug stem (3) onto the body (1).Make sure that the marking on the valve bonnet are aligned with the front of the valve (see Fig. 6).

NOTICE!

NOTICE!

NOTICE!



EB 8115 EN 21


2

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Marking on the valve bonnet

Front of the valve


Fig. 5: Type 3321CT Valve

Fig. 6: Aligning the valve bonnet

22 EB 8115 EN


Make sure that the gasket (13) is seated properly in the body.

9. Apply a suitable lubricant to the hexa-gon screws (10).

10. Firmly press the plug (3) into the seat (2), while fastening down the valve bonnet (7) with the hexagon screws (10). Tight-en the screws gradually in a crisscross pattern. Observe tightening torques.

11. For further instructions concerning Type 3379 Actuator (pneumatic connec-tions, alignment of the actuator, etc.) u EB 8315.

5.2 Installing the valve into the pipeline

5.2.1 Checking the installation conditions

Pipeline routingThe inlet and outlet lengths vary depending on the process medium. To ensure the control valve functions properly, follow the installa-tion instructions given below:

Î Observe the inlet and outlet lengths (see Table 3). Contact SAMSON if the valve conditions or state of the medium process deviate.

Î Install the valve free of stress and with the least amount of vibrations as possible. If necessary, attach supports to the valve.

Î Install the valve allowing sufficient space to remove the actuator and valve or to perform service and repair work on them.

Mounting positionGenerally, we recommend installing the valve with the actuator upright and on top of the valve.

Î Contact SAMSON if the mounting posi-tion is not as specified above.

Support or suspensionDepending on the valve version and mount-ing position, the control valve and pipeline must be supported or suspended. The plant engineering company is responsible in this case.

Premature wear and leakage due to insuffi-cient support or suspension.In the following versions, the control valve must be supported or suspended: − Valves that are not installed with the actua-tor in the upright position on top of the valve.

Attach a suitable support or suspension to the valve.

Vent plugVent plugs are screwed into the exhaust air ports of pneumatic and electropneumatic de-vices. They ensure that any exhaust air that forms can be vented to the atmosphere (to avoid excess pressure in the device). Further-more, the vent plugs allow air intake to pre-vent a vacuum from forming in the device.

Î Locate the vent plug on the opposite side to the workplace of operating personnel.

NOTICE!


EB 8115 EN 23


Table 3: Inlet and outlet lengths

Q

a x DN b x DNa x NPS b x NPS

State of process medium Valve conditions Inlet length a Outlet length b

GasMa ≤ 0.3 2 4

0.3 ≤ Ma ≤ 0.7 2 10

Vapor

Ma ≤ 0.3 1) 2 4

0.3 ≤ Ma ≤ 0.7 1) 2 10

Saturated steam (percentage of condensate > 5 %) 2 20

Liquid

Free of cavitation/w < 10 m/s 2 4

Cavitation producing noise/w ≤ 3 m/s 2 4

Cavitation producing noise/3 < w < 5 m/s 2 101) No saturated steam

Q Flow ratea Inlet lengthb Outlet length

24 EB 8115 EN


Î On mounting valve accessories, make sure that they can be operated from the workplace of the operating personnel.

The workplace of operating personnel is the location from which the valve, actuator and any mounted valve accessories can be ac-cessed to operate them.

5.2.2 Additional fittingsStrainersWe recommend installing a SAMSON strainer upstream of the valve. It prevents sol-id particles in the process medium from damaging the valve.

Bypass and shut-off valvesWe recommend installing a shut-off valve both upstream of the strainer and down-stream of the valve and installing a bypass line. The bypass ensures that the plant does not need to be shut down for service and re-pair work on the valve.

5.2.3 Installing the control valve

1. Close the shut-off valve in the pipeline while the valve is being installed.

2. Remove the protective caps from the valve ports before installing the valve.

3. Lift the valve using suitable lifting equip-ment to the site of installation (see sec-tion 4.2.2). Observe the flow direction

through the valve. The arrow on the valve indicates the direction of flow.

4. Make sure that the correct flange gaskets are used.

5. Bolt the pipe to the valve free of stress.6. Depending on the field of application,

allow the valve to cool down or heat up to reach ambient temperature before start up.

7. Slowly open the shut-off valve in the pipeline after the valve has been in-stalled.

Risk of valve damage due to a sudden pres-sure increase and resulting high flow veloci-ties.Slowly open the shut-off valve in the pipeline during start-up.

8. Check the valve to ensure it functions properly.

5.3 Preparing for operationProceed as follows:

Î Flush the pipelines. Î Check the valve to make sure it is clean.


Note

NOTICE!

NOTICE!

EB 8115 EN 25


5.4 Quick checkSAMSON valves are delivered ready for use. To test the valve's ability to function, the following quick checks can be performed:

Tight shut-off1. Close the valve.2. Slowly open the shut-off valve in the

pipeline.

Risk of valve damage due to a sudden pressure increase and resulting high flow velocities.Slowly open the shut-off valve in the pipeline during start-up.

3. Check the valve for leakage (visual in-spection).

Travel motionThe movement of the actuator stem must be linear and smooth.

Î Open and close the valve, observing the movement of the actuator stem.

Î Apply the maximum and minimum con-trol signals to check the end positions of the valve.

Fail-safe position Î Shut off the signal pressure line. Î Check whether the valve moves to the fail-safe position.

Pressure testDuring the pressure test, make sure the fol-lowing conditions are met:

− Retract the plug stem to open the valve. − Observe the maximum permissible pres-

sure for valve and plant.

The plant operator is responsible for performing the pressure test. SAMSON's After-sales Service department can support you to plan and perform a pressure test for your plant.

NOTICE!

Note

26 EB 8115 EN

Operation

6 OperationThe valve is ready for use when mounting and start-up (see section 5) have been com-pleted.

Risk of personal injury when the actuator vents.Wear eye protection when working in close proximity to the control valve.

Risk of burn injuries due to hot or cold com-ponents and pipelines.Depending on the process medium, valve components and pipelines may get very hot or cold and cause burn injuries.Wear protective clothing and safety gloves.

Operation disturbed by a blocked actuator or plug stem.Do not impede the movement of the actuator or plug stem by inserting objects into their path.

WARNING!

WARNING!

NOTICE!

EB 8115 EN 27

Servicing

7 ServicingThe control valve is subject to normal wear, especially at the seat, plug and packing. De-pending on the operating conditions, check the valve at regular intervals to prevent pos-sible failure before it can occur.

SAMSON's After-sales Service department can support you in drawing up an inspection and test plan for your plant.

We recommend removing the valve from the pipeline for service or repair work (see sec-tion 9.2).

Risk of bursting in pressure equipment.Valves and pipelines are pressure equip-ment. Improper opening can lead to bursting of the valve. − Before starting any work on the valve, de-pressurize all plant sections concerned as well as the valve. − Drain the process medium from all the plant sections concerned as well as the valve. − Wear personal protective equipment.

Risk of personal injury due to residual pro-cess medium in the valve.While working on the valve, residual process medium can escape and, depending on its properties, may lead to personal injury, e.g. (chemical) burns.

Wear protective clothing, safety gloves, and eyewear.

Risk of burn injuries due to hot or cold com-ponents and pipeline.Valve components and the pipeline may be-come very hot or cold. Risk of burn injuries. − Allow components and pipelines to cool down or heat up. − Wear protective clothing and safety gloves.

Risk of valve damage due to incorrect servic-ing or repair.Service and repair work must only be performed by trained staff.

Risk of valve damage due to excessively high or low tightening torques.Observe the specified torques on tightening control valve components. Excessively tight-ened torques lead to parts wearing out quicker. Parts that are too loose may cause leakage.Observe the specified tightening torques (u AB 0100).

Risk of valve damage due to the use of un-suitable tools.Only use tools approved by SAMSON (u AB 0100).

Tip

DANGER!

WARNING!

WARNING!

NOTICE!

NOTICE!

NOTICE!



28 EB 8115 EN

Servicing

Risk of valve damage due to the use of un-suitable lubricants.Only use lubricants approved by SAMSON (u AB 0100).


The control valve was checked by SAMSON before it left the factory. − Certain test results (seat leakage and leak test) certified by SAMSON lose their validity when the valve body or actuator housing is opened. − The product warranty becomes void if service or repair work not described in these instructions is performed without prior agreement by SAMSON's After-sales Service department. − Only use original spare parts by SAMSON, which comply with the original specifications.

Preparing the valve for servicing1. Put the control valve out of operation (see

section 9.1).

2. Remove the valve from the pipeline (see section 9.2).

3. Make sure that the valve is completely open (the plug stem is completely retract-ed).Version with "actuator stem extends" fail-safe action: apply a signal pressure that corresponds to the upper bench range value to the connection on the bot-tom diaphragm chamber.Version with "actuator stem retracts" fail-safe action: make sure that no signal pressure is applied to the actuator.

7.1 Replacing the gasket1. Undo the hexagon screws (10) on the

valve bonnet (7).2. Lift the actuator, flange (14), valve bon-

net (7) and plug with plug stem (3) off the body (1).

3. Remove the gasket (13). Carefully clean the sealing faces in the valve body (1) and on the flange bonnet (7).

4. Insert a new gasket (13) into the body.5. Carefully place the actuator, valve bon-

net (7), flange (14) and plug with plug stem (3) onto the body (1).Make sure that the marking on the valve bonnet are aligned with the front of the valve (see Fig. 6).


7. Firmly press the plug (3) into the seat (2), while fastening down the valve bonnet (7) with the hexagon screws (10). Tight-

NOTICE!

NOTICE!

Note


EB 8115 EN 29

Servicing

2

3

1014

134

1

87

Marking on the valve bonnet

Front of the valve


Fig. 7: Type 3321CT Valve

Fig. 8: Aligning the valve bonnet

30 EB 8115 EN

Servicing

3 Plug stem4 Guide bushing5 Spring6 Washer

8 V-ring packing9 Spacer

11 Retaining washer12 Snap ring

8

11

93

4

5

12

6

Fig. 9: Packing

11

3

Fig. 10: Aligning the retaining washer

en the screws gradually in a crisscross pattern. Observe tightening torques.

7.2 Replacing the packing1. Undo the hexagon screws (10) on the

valve bonnet (7).2. Lift the actuator, flange (14), valve bon-

net (7) and plug with plug stem (3) off the body (1).

3. Replace the gasket as described in sec-tion 7.1.

4. Unscrew the valve bonnet (7) from the actuator base.

5. Unscrew the plug stem (3) from the actu-ator stem.

6. Pull the plug with plug stem (5) out of the valve bonnet (7).

7. Pull all the packing parts out of the pack-ing chamber using a suitable tool.

8. Renew damaged parts. Clean the pack-ing chamber thoroughly.

9. Apply a suitable lubricant to all the pack-ing parts and to the plug stem (3).

10. Make sure that the guide bushing (4) and spacer (9) are seated correctly in the valve bonnet (7).

11. Insert the packing parts into the packing chamber. Observe the proper sequence (see Fig. 9).

12. Place the retaining ring (12) on the pack-ing parts.

13. Use a suitable tool to press the packing together until the retaining ring (12) is seated in the groove of the valve bonnet (7).

EB 8115 EN 31

Servicing

14. Place the retaining washer (11) from above onto the plug stem (3). Observe the proper alignment (see Fig. 10).

15. Carefully slide the plug stem (3) into the valve bonnet (7).





20. Carefully place the actuator, valve bon-net (7), flange (14) and plug with plug stem (3) onto the body (1).Make sure that the marking on the valve bonnet are aligned with the front of the valve (see Fig. 8).Make sure that the gasket (13) is seated properly in the body.




7.3 Replacing the seat and plug

Risk of damage to the facing of the seat and plug due to incorrect service or repair.Always replace both the seat and plug.

When replacing the seat and plug, we also recommend replacing the gasket and pack-ing. See sections 7.1 and 7.2.

1. Undo the hexagon screws (10) on the valve bonnet (7).

2. Lift the actuator, flange (14), valve bon-net (7) and plug with plug stem (3) off the body (1).

3. Replace the gasket as described in sec-tion 7.1.

4. Unscrew the seat (4) using a suitable tool.

5. Apply a suitable lubricant to the thread and the sealing cone of the new seat.

6. Screw in the seat (4). Observe tightening torques.

7. Unscrew the valve bonnet (7) from the actuator base.

8. Unscrew the plug stem (3) from the actu-ator stem.

9. Pull the plug with plug stem (5) out of the valve bonnet (7).

10. Pull all the packing parts out of the pack-ing chamber using a suitable tool.

NOTICE! NOTICE!

Tip


32 EB 8115 EN

Servicing

11. Apply a suitable lubricant to all the pack-ing parts and to the new plug stem (3). We recommend replacing the packing as well. See section 7.2.

12. Make sure that the guide bushing (4) and spacer (9) are seated correctly in the valve bonnet (7).

13. Insert the packing parts into the packing chamber. Observe the proper sequence (see Fig. 9).

14. Place the retaining ring (12) on the pack-ing parts.

15. Use a suitable tool to press the packing together until the retaining ring (12) is seated in the groove of the valve bonnet (7).

16. Place the retaining washer (11) from above onto the new plug stem (3). Ob-serve the proper alignment (see Fig. 10).

17. Carefully slide the new plug stem with plug (3) into the valve bonnet (7).





22. Carefully place the actuator, valve bon-net (7), flange (14) and plug with plug stem (3) onto the body (1).

Make sure that the marking on the valve bonnet are aligned with the front of the valve (see Fig. 8).Make sure that the gasket (13) is seated properly in the body.




7.4 Preparation for return ship-ment

Defective valves can be returned to SAMSON for repair.Proceed as follows to return devices to SAMSON:1. Put the control valve out of operation (see

section 9).2. Decontaminate the valve. Remove any

residual process medium.3. Fill in the Declaration on Contamination,

which can be downloaded from our website at u www.samson.de > SERVICE & SUPPORT > After-sales Service > Dec-laration on Contamination.

4. Send the valve together with the filled-in form to your nearest SAMSON subsidiary. SAMSON subsidiaries are


https://www.samson.de/fileadmin/user_upload/service/aftersales/1700-0267_en.pdf



EB 8115 EN 33

Servicing

listed on our website at u www.samson.de > About SAMSON.

7.5 Ordering spare parts and operating supplies

Contact your nearest SAMSON subsidiary or the SAMSON After-sales Service depart-ment for information on spare parts, lubri-cants and tools.

Spare partsSee section 10.3 for details on spare parts.

LubricantsDetails on suitable lubricants can be found in the document u AB 0100.

ToolsDetails on suitable tools can be found in the document u AB 0100.

https://www.samson.de/en/ueber-samson/auf-einen-blick/



34 EB 8115 EN

Malfunctions

8 MalfunctionsDepending on the operating conditions, check the valve at certain intervals to prevent possi-ble failure before it can occur. Operators are responsible for drawing up an inspection and test plan.

SAMSON's After-sales Service department can support you in drawing up an inspection and test plan for your plant.

8.1 TroubleshootingFaults Possible reasons Recommended actionActuator or plug stem does not move on demand.

Actuator is blocked. Check attachment.Unblock the actuator.

Signal pressure too low Check the signal pressure.Check the signal pressure line for leakage.

Actuator or plug stem does not move through the whole range.

Signal pressure too low Check the signal pressure.Check the signal pressure line for leakage.

The valve leaks to the atmosphere (fugitive emissions).

The packing is defective. Replace packing (see section 7.2) or contact SAMSON's After-sales Service department.

Flange joint loose or gasket worn out.

Check the flange joint.Replace gasket at the flanged joint (see section 7.1 or contact SAMSON's After-sales Service department).

Increased flow through closed valve (seat leakage)

Dirt or other foreign particles deposited between the seat and plug.

Shut off the section of the pipeline and flush the valve.

Valve trim, particularly with soft seat, is worn.

Replace seat and plug (see section 7.3 or contact SAMSON's After-sales Service department).

Tip

EB 8115 EN 35

Malfunctions

Contact SAMSON's After-sales Service de-partment for malfunctions not listed in the ta-ble.

8.2 Emergency actionUpon supply air or control signal failure, the valve moves to its fail-safe position (see sec-tion 3.1).The plant operator is responsible for emer-gency action to be taken in the plant.In the event of a valve malfunction:1. Close the shut-off valves upstream and

downstream of the control valve to stop the process medium from flowing through the valve.

2. Check the valve for damage. If neces-sary, contact SAMSON's After-sales Ser-vice department.

Putting the valve back into operation after a malfunction

Î Slowly open the shut-off valves. Allow the process medium to slowly flow into the valve.

Note

36 EB 8115 EN

Decommissioning and disassembly

9 Decommissioning and disas-sembly

Risk of bursting in pressure equipment.Valves and pipelines are pressure equip-ment. Improper opening can lead to bursting of the valve. − Before starting any work on the valve, de-pressurize all plant sections concerned as well as the valve. − Drain the process medium from all the plant sections concerned as well as the valve. − Wear personal protective equipment.

Risk of personal injury due to residual pro-cess medium in the valve.While working on the valve, residual process medium can escape and, depending on its properties, may lead to personal injury, e.g. (chemical) burns.Wear protective clothing, safety gloves, and eyewear.

Risk of burn injuries due to hot or cold com-ponents and pipeline.Valve components and the pipeline may be-come very hot or cold. Risk of burn injuries. − Allow components and pipelines to cool down or heat up. − Wear protective clothing and safety gloves.

9.1 DecommissioningTo decommission the control valve for service and repair work or disassembly, proceed as follows:1. Close the shut-off valves upstream and

downstream of the control valve to stop the process medium from flowing through the valve.

2. Completely drain the pipelines and valve.

3. Disconnect and lock the pneumatic air supply to depressurize the actuator.

4. If necessary, allow the pipeline and valve components to cool down or heat up.

9.2 Removing the valve from the pipeline

1. Put the control valve out of operation (see section 9.1).

2. Unbolt the flange joint.3. Remove the valve from the pipeline (see

section 4.2).

9.3 Disposal Î Observe local, national and internation-al refuse regulations.

Î Do not dispose of components, lubricants and hazardous substances together with your household waste.

DANGER!

WARNING!

WARNING!

EB 8115 EN 37

Appendix

10 Appendix

10.1 After-sales serviceContact SAMSON's After-sales Service de-partment for support concerning service or repair work or when malfunctions or defects arise.

E-mailYou can reach the After-sales Service De-partment at [email protected].

Addresses of SAMSON AG and its subsid-iariesThe addresses of SAMSON AG, its subsid-iaries, representatives and service facilities worldwide can be found on the SAMSON website (www.samson.de) or in all SAMSON product catalogs.

Required specificationsPlease submit the following details: − Order number and position number in

the order − Type, model number, nominal size and

valve version − Pressure and temperature of the process

medium − Flow rate in m³/h − Bench range of the actuator (e.g. 2.3 to

3.7 bar) − Is a strainer installed? − Installation drawing

10.2 CertificatesThe EU declaration of conformity is provided on the next page.

38 EB 8115 EN

Vaulx-en-Velin, 10/05/17 B.Lauterjung J. Signoles-Fontaine Responsable du Bureau d’Etudes/ Leiter der Entwicklung Responsable Qualité / Leiter der Qualitätssicherung Design Manager Quality manager

DECLARATION DE CONFORMITE A LA DIRECTIVE EQUIPEMENTS SOUS PRESSION 2014/68/UE

N° PED-030 Fabricant : Samson Régulation SA 1, rue Jean Corona F-69511 Vaulx-en-Velin Cedex Description de l’équipement sous pression : Vanne de régulation 2 voies type 3321 Matière des corps: 1.0619/A216WCC, 1.4408/A351 CF8M

DN 15 - 25 NPS ½ - 1

Classement de l’équipement selon la Directive: Tuyauterie visée à l’article 4 point 3

DN 32 - 100 NPS 1 ½ - 4

Classement de l’équipement selon la Directive: Tuyauterie visée à l’article 4 point 1.c) tout type de fluide Procédure d’évaluation de conformité utilisée: Module H assurance complète de qualité concernée par l'approbation: N° CE-PED-H-SAM 001-17-FRA émise par le Bureau Veritas le 28/04/17.

Nom et adresse de l’organisme notifié effectuant le contrôle : Bureau Veritas S.A. Newtime 52 Bd du Parc – Ile de la Jatte 92200 NEUILLY-SUR-SEINE Normes utilisées pour la conception: DIN-EN 12 516-2, ASME B 16.34, DIN-EN 1092-1, DIN-EN 60534-4 Autres Directives Européennes prises en compte le cas échéant : 98/37/CE, 2006/42/CE, 93/68/CEE, 2006/95/CE, 2004/108/CE, 94/9/CE.

KONFORMITÄTSERKLÄRUNG GEMÄSS DRUCKGERÄTE-RICHTLINIE 2014/68/EG

Nr PED-030 Hersteller : Samson Régulation SA 1, rue Jean Corona F-69511 Vaulx-en-Velin Cedex Beschreibung des Druckgerätes : Durchgangsventil Typ 3321 Gehäusewerkstoff : 1.0619/A216WCC, 1.4408/A351 CF8M DN 15 - 25 NPS ½ - 1

Die Geräte sind geeignet für Medien gemäss: Rohrleitung Artikel 4 Nummer 3

DN 32 - 100 NPS 1 ½ - 4

Die Geräte sind geeignet für Medien gemäss: Rohrleitung Artikel 4 Nummer 1.c) alle Fluide Angewandtes Konformitätsbewertungsverfahren:

Modul H umfassende Qualitätversicherung betreffen die Übereinstimmung: Nr CE-PED-H-SAM 001-17-FRA des Bureau Veritas vom 28/04/17.

Name und Anschrift der benannten Stelle, welche das Qualitätssicherungssystem überwacht: Bureau Veritas S.A. Newtime 52 Bd du Parc – Ile de la Jatte 92200 NEUILLY-SUR-SEINE Dem Entwurf zugrundegelegt sind die Verfahren aus: DIN-EN 12 516-2, ASME B 16.34, DIN-EN 1092-1, DIN-EN 60534-4 Andere eventuell angewandte Gemeinschaftsrichtlinien: 98/37/EG, 2006/42/EG, 93/68/EWG, 2006/95/EG, 2004/108/EG, 94/9/EG.

DECLARATION OF CONFORMITY TO THE PRESSURE EQUIPMENT DIRECTIVE 2014/68/EU

Nb PED-030

Manufacturer: Samson Régulation SA 1, rue Jean Corona F-69511 Vaulx-en-Velin Cedex Description of pressure equipment: 2-way Valve type 3321 Material of the body: 1.0619/A216WCC, 1.4408/A351 CF8M DN 15 - 25 NPS ½ - 1

Classification of the equipment: Acc. to piping article 4 paragraph 3

DN 32 - 100 NPS 1 ½ - 4

Classification of the equipment: Acc. to piping article 4 paragraph 1.c) all kinds of fluids Conformity assessment procedure followed: Module H complete insurance of quality concerned by the approval: Nb. CE-PED-H-SAM 001-17-FRA from Bureau Veritas on 28/04/17.

Name and address of notified body: Bureau Veritas S.A. Newtime 52 Bd du Parc – Ile de la Jatte 92200 NEUILLY-SUR-SEINE Standards and specifications used: DIN-EN 12 516-2, ASME B 16.34, DIN-EN 1092-1, DIN-EN 60534-4. Other eventual Community Directives applied: 98/37/EC, 2006/42/EC, 93/68/EEC, 2006/95/EC, 2004/108/EC, 94/9/EC.

EB 8115 EN 39

10.3 Spare parts

1 Body2 Seat3 Plug4 Guide bushing5 Spring6 Washer7 Valve bonnet8 V-ring packing9 Spacer10 Hexagon screw11 Retaining washer12 Snap ring13 Body gasket14 Flange

1

13

2

3

7

14

10

49

8

65612

9

Type 3379

Type 3321CT

SAMSON AG · MESS- UND REGELTECHNIKWeismüllerstraße 3 · 60314 Frankfurt am Main, GermanyPhone: +49 69 4009-0 · Fax: +49 69 [email protected] · www.samson.de EB 8115 EN 20

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