Samson 3241-7 Manuel de service

Pneumatic Control Valves

Type 3241-1 and Type 3241-7

Mounting and

Operating Instructions

EB 8015 EN

Edition September 2009

Fig. 1 · Type 3241 Valve with Type 3271 Actuator and with Type 3277 Actuator

Type 3241-7

Type 3241-1

Contents Page

1 Design and principle of operation. . . . . . . . . . . . . . . . . . . . 4

2 Assembling valve and actuator. . . . . . . . . . . . . . . . . . . . . . 4

2.1 Assembly and adjustment . . . . . . . . . . . . . . . . . . . . . . . . 4

2.2 Pretensioning springs in actuator version “Actuator stem extends”. . . . . 7

2.3 Valve and actuator with different rated travels . . . . . . . . . . . . . . 8

3 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

3.1 Mounting position. . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

3.2 Signal pressure line . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

3.3 Strainer, bypass . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

3.4 Test connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

4 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

5 Maintenance – Replacing parts . . . . . . . . . . . . . . . . . . . . . 10

5.1 Standard valve version. . . . . . . . . . . . . . . . . . . . . . . . . 11

5.1.1 Stuffing box packing. . . . . . . . . . . . . . . . . . . . . . . . . . 11

5.1.2 Seat and/or plug . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

5.2 Valve with extension bonnet or metal bellows seal . . . . . . . . . . . 13

5.2.1 Stuffing box packing. . . . . . . . . . . . . . . . . . . . . . . . . . 13

5.2.2 Plug. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

5.2.3 Seat. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

5.2.4 Metal bellows . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

5.2.5 Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

5.3 Replacing the collar or seal . . . . . . . . . . . . . . . . . . . . . . 16

6 Material identification . . . . . . . . . . . . . . . . . . . . . . . . . 18

6.1 Identification marks . . . . . . . . . . . . . . . . . . . . . . . . . . 18

6.2 Seat code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

7 Description of nameplates . . . . . . . . . . . . . . . . . . . . . . . 20

8 Customer inquiries . . . . . . . . . . . . . . . . . . . . . . . . . . 21

2EB 8015 EN

Contents

Note! Non-electrical control valves which do not have a valve body lined with an insulating

material coating do not have their own potential ignition source according to the risk assess-

ment in the rare incident of an operating fault, corresponding to EN 13463-1: 2001 para-

graph 5.2, and therefore do not fall within the scope of the European Directive 94/9/EC.

Refer to paragraph 6.3 of EN 60079-14:1977 VDE 0165 Part 1 concerning connection to

equipotential bonding system.

These Mounting and Operating Instructions apply also to Type 3246 Globe Valve

(Class 150 and 300) in conjunction with Data Sheet T 8046-1 EN.

EB 8015 EN 3

Safety instructions

General safety instructions

The control valve may only be mounted, started up or serviced by fully

trained and qualified personnel, observing the accepted industry codes and

practices. Make sure employees or third persons are not exposed to any

danger. All safety instructions and warnings in these mounting and

operating instructions, particularly those concerning assembly, start-up and

maintenance, must be observed.

The control valves fulfill the requirements of the European Pressure

Equipment Directive 97/23/EC. Valves with a CE marking have a

declaration of conformity that includes information about the applied

conformity assessment procedure. The declaration of conformity is available

on request.

For appropriate operation, make sure that the control valve is only used in

areas where the operating pressure and temperatures do not exceed the

operating values which are based on the valve sizing data submitted in the

order. The manufacturer does not assume any responsibility for damage

caused by external forces or any other external influence! Any hazards

which could be caused in the control valve by the process medium,

operating pressure, signal pressure or by moving parts are to be prevented

by means of the appropriate measures.

Proper shipping and appropriate storage are assumed.

Caution!

For installation and maintenance work on the valve, make sure the relevant

section of the pipeline is depressurized and, depending on the process

medium, drained as well. If necessary, allow the control valve to cool down

or warm up to reach ambient temperature prior to starting any work on the

valve.

Prior to performing any work on the valve, make sure the supply air and

control signal are disconnected or blocked to prevent any hazards that could

be caused by moving parts.

Special care is needed when the actuator springs are preloaded. These

actuators are labeled correspondingly and can also be identified by three

long bolts at the bottom of the actuator. Prior to starting any work on the

valve, you must relieve the compression from the preloaded springs.

1 Design and principle of opera-

tion

The Type 3241-1 and Type 3241-7 Pneu-

matic Control Valves consist of a Type 3241

single-seated Globe Valve and either a

Type 3271 or Type 3277 Pneumatic Actua-

tor.

Thanks to the modular design, the actuators

can be exchanged, and the standard version

of the valve can be supplemented to form a

version with extension bonnet or metal bel-

lows seal.

In the micro-flow valve version, a micro-trim

element is installed in the valve body instead

of the usual seat-plug assembly.

The process medium flows through the valve

in the direction indicated by the arrow. The

position of the plug (3) determines the flow

through the valve seat (2). The position of

the plug (3) is changed by the signal pres-

sure acting on the diaphragm of the actua-

tor (bench range). Plug (3) and actuator

stem (8.1) are connected by the stem con-

nector (7) and sealed by the spring-loaded

ring packing (4.2).

Fail-safe position

The control valve provides two different

fail-safe positions depending on the ar-

rangement of the springs in the actuator:

Actuator stem extends

When the signal pressure is reduced or the

power supply or signal fails, the springs

move the actuator stem downwards and

close the valve.

When the signal pressure increases again,

the valve opens acting against the force of

the springs.

Actuator stem retracts

When the signal pressure is reduced or the

power supply or signal fails, the springs

move the actuator stem upwards and open

the valve.

When the signal pressure increases again,

the valve closes acting against the force of

the springs.

2 Assembling valve and actuator

The basic pneumatic actuator can be re-

placed by an electric actuator or a pneu-

matic actuator with additional handwheel.

A pneumatic actuator (with or without

handwheel) can be exchanged for another

pneumatic actuator in a different size.

If, in the valve-actuator assembly, the travel

range of the actuator is larger than the

travel range of the control valve, the actua-

tor springs are preloaded by the manufac-

turer so that the travels match.

2.12.1 Assembly and adjustment

If the valve and actuator have not been

pre-assembled by the manufacturer, or if the

actuator of a valve is to be replaced by an

actuator of another type or another size,

proceed as described below.

1. Unscrew the lock nut (6.2) and stem con-

nector nut (6.1).

Firmly press the plug together with the

plug stem into the seat ring. Make sure

the large V-shaped port of the V-port

plug faces towards the valve outlet.

Thread the stem connector nut and lock

nut downwards.

4EB 8015 EN

Design and principle of operation

EB 8015 EN 5

Assembling valve and actuator

Fig, 2 · Sectional drawings

1. Valve body

1.1 Nuts

1.2 Gasket

2 Seat

3 Plug

4.1 Spring

4.2 Packing

5 Valve bonnet

5.2 Threaded bushing

5.3 Travel indicator scale

6 Plug stem

6.1 Stem connector nut

6.2 Lock nut

6.3 Yoke

(DN 200 to DN 300)

7 Stem connector

8 Actuator

8.1 Actuator stem

8.2 Nut

5.3

6.1

6.2

5.2

4.2

4.1

8.2

8.1

1.1

1.2

Type 3271 Actuator

Type 3241 Valve

Micro-trim element

15 Plug stem

16 Valve plug

17 Seat body

18 Spring

19 Seat nut

6EB 8015 EN

Assembling valve and actuator

Fig. 3 · Sectional drawings of Type 3241-7 and valve body DN 200 to DN 300

8.1

8.2

6.1

1.1

4.1

1.2

4.2

5.2

6.2

5.3

6.3

1 Valve body

1.1 Nuts

1.2 Gasket

2 Seat

3 Plug

4.1 Spring

4.2 Packing

5 Valve bonnet

5.2 Threaded bushing

5.3 Travel indicator scale

6 Plug stem

6.1 Stem connector nut

6.2 Lock nut

6.3 Yoke (DN 200 to DN 300)

7 Stem connector

8 Actuator

8.1 Actuator stem

8.2 Nut

Type 3277 Actuator

2. Remove the stem connector clamps (7)

and the ring nut (8.2) from the actuator

(8). Slide the ring nut over the plug stem.

3. Place actuator onto the valve bonnet (5)

and secure with the ring nut (8.2).

4. Read bench range (or bench range with

pre-loaded springs) and fail-safe action

from the actuator's nameplate (e.g. 0.2

to 1 bar and "Actuator stem extends").

The lower value of the bench range

(0.2 bar) corresponds to the lower bench

range value to be adjusted; the upper bench

range value (1 bar) corresponds to the

upper bench range value. The fail-safe ac-

tion "Actuator stem extends" (FA) or "Actua-

tor stem retracts" (FE) is indicated on the

Type 3271 Actuator. The Type 3277 Actua-

tor bears the corresponding symbol.

5. For actuators with "Actuator stem ex-

tends", apply a signal pressure to the

lower diaphragm chamber which corre-

sponds to the lower bench range value

(e.g. 0.2 bar).

For actuators with "Actuator stem re-

tracts", apply a signal pressure to the

upper diaphragm chamber which corre-

sponds to the upper bench range value

(e.g. 1 bar).

6. Thread down the stem connector nut

(6.1) by hand until it makes contact with

the actuator stem (8.1). Then, turn it an-

other 1/4 turn and secure this position

with the lock nut (6.2).

7. Position the stem connector clamps (7)

and screw tight. Align the travel indica-

tor scale (5.3) with the tip of the stem

connector.

Note on disassembling an actuator!

Before disassembling an actuator with

fail-safe action "Actuator stem extends" and

particularly an actuator with preloaded

springs, apply a pressure to the lower signal

pressure connection that slightly exceeds the

lower bench range value (see nameplate of

the actuator), so that you can loosen the ring

nut (8.2).

2.2 Pretensioning springs in

actuator version “Actuator

stem extends”

To achieve a greater positioning force, the

springs in actuators with "Actuator stem ex-

tends" can be preloaded with up to 12.5 %

(actuator sizes 120 and 240 cm²) or up to

25 % (350 cm² and higher) of their travel or

bench range.

Example:

If the springs are preloaded with, for exam-

ple, 0.1 bar for a bench range of 0.2 to

1 bar, the bench range is shifted by 0.1 bar

to result in a bench range of 0.3 to 1.1 bar

(0.1 bar corresponds to a preload of

12.5 %).

When adjusting the valve, the lower bench

range is to be set to 0.3 bar. Make sure the

new bench range of 0.3 to 1.1 bar is indi-

cated on the nameplate as the bench range

with preloaded springs!

EB 8015 EN 7

Assembling valve and actuator

2.3 Valve and actuator with

different rated travels

Actuator version "Actuator stem extends"

Note!

Valves that have a travel smaller than the

rated travel of the actuator always need to

use preloaded springs.

Example:

Valve DN 100 with 30 mm rated travel and

1400 cm² actuator with 60 mm rated travel,

0.4 to 2 bar bench range.

1. Set the signal pressure required for

tensioning the springs above the signal

pressure of 1.2 bar (1.2 to 2 bar range)

which corresponds to the mid actuator

travel (30 mm) to 1.6 bar.

2. Thread stem connector nut (6.1) until it

touches the actuator stem.

3. Secure the position with lock nut and at-

tach stem connector as described in sec-

tion 2.1.

4. Enter the 1.6 to 2.4 bar bench range

valid for the mounted valve on the

nameplate of the actuator.

Actuator version "Actuator stem retracts"

Note!

The springs in the actuator version “Actuator

stem retracts” cannot be preloaded!

If a valve is to be attached to a larger actua-

tor (rated travel of actuator larger than the

rated travel of the valve), just the first half of

the bench range of the actuator can be

used.

Example:

Valve DN 100 with 30 mm rated travel and

1400 cm² actuator with 60 mm rated travel,

0.4 to 1 bar bench range:

A useable bench range of 0.2 to 0.6 bar is

available for the half valve range.

Caution!

Actuators which have been

preloaded by the manufacturer

without an attached valve are

marked with a label.

In addition, you will notice three

extended bolts on the bottom

diaphragm case. They enable you to

evenly relieve the compressed

springs when disassembling the

actuator.

8EB 8015 EN

Assembling valve and actuator

3 Installation

3.1 Mounting position

The valve can be mounted in any desired

position. However, vertical installation with

the actuator pointing upwards is preferable

for valves in nominal size DN 100 or larger

to facilitate maintenance.

For valves with extension bonnet or metal

bellows seal, or for actuators weighing more

than 50 kg, mount a suitable support or sus-

pension for the actuator.

Note!

The valve must be installed with the least

amount of vibrations possible and without

any stress.

Piping design

To allow the control valve to work properly,

the pipeline upstream and downstream of

the valve should be straight and free of ob-

structions for a length of at least 6 times the

pipe diameter (DN).

Contact SAMSON if this length cannot be

met during installation.

Clean out the pipeline thoroughly prior to in-

stalling the valve.

Note!

Valves that should meet the requirements of

NACE MR 0175 standard should not be in-

sulated.

3.2 Signal pressure line

Connect the signal pressure line to the lower

diaphragm case for valves with actuator

version "Actuator stem extends" and to the

upper diaphragm case for valves with actu-

ator version "Actuator stem retracts".

The lower signal pressure connection of the

Type 3277 Actuator is located at the side of

the yoke of the lower diaphragm case.

3.3 Strainer, bypass

We recommend you to install a SAMSON

Type 2 Strainer upstream of the valve body.

We also recommend to install a shut-off

valve both upstream of the strainer and

downstream of the valve, as well as a by-

pass, so that you do not need to shut down

the plant for maintenance.

3.4 Test connection

If there is a test connection (G 1/8) at the

upper flange of a valve version with metal

bellows seal (Fig. 6), you can check the

tightness of the bellows there.

Particularly for liquids and vapors, we rec-

ommend you to install a suitable leak indica-

tor at the test connection, such as a contact

pressure gauge, an outlet into an open ves-

sel or an inspection window.

4 Operation

(e.g. reversing the fail-safe action of the ac-

tuator etc.)

For details concerning operation, see

Mounting and Operating Instructions

EB 8310 EN for the Type 3271 Pneumatic

Actuator and

EB 8311 EN for the Type 3277 Pneumatic

Actuator.

EB 8015 EN 9

Installation

5 Maintenance – Replacing parts

The control valve is subject to natural wear,

especially at the seat, plug and packing.

Depending on the application, the valve

needs to be checked regularly to prevent

against possible failures.

If leakage occurs, this could be caused by a

damaged packing or a defective metal bel-

lows.

If the valve does not seal properly, the tight

shut-off may be impeded by dirt or other im-

purities caught between the seat and plug,

or by damaged seating surfaces.

Remove the parts, clean them thoroughly

and replace them with new ones, if neces-

sary.

Note!

When mounting the bonnet, the large

V-shaped port of the V-port plug must face

towards the valve outlet.

Caution!

Before servicing or disassembling the

control valve, depressurize the con-

cerned section of the plant and drain

it, if necessary, depending on the

medium used. Switch off the signal

pressure for the actuator and remove

the signal pressure line. As valves

are not free of cavities, there might

still be residual medium in the valve.

This applies, in particular, for valve

versions with extension bonnet and

metal bellows seal.

Caution!

On performing any work on the valve, first

shut off the signal pressure, disconnect the

signal pressure line and remove the actua-

tor.

Note!

Suitable seat and special tools as well as the

appropriate tightening torques required for

installation are listed in EB 029 EN (formerly

WA 029 EN). The instructions can be

viewed on the Internet at

www.samson.de/pdf_en/e00290en.pdf.

Removing the actuator:

1. Before disassembling an actuator with

fail-safe action "Actuator stem extends"

and particularly an actuator with

preloaded springs, apply a pressure to

the lower signal pressure connection that

slightly exceeds the lower bench range

value (see nameplate), so that you can

remove the ring nut (8.2). Remove the

stem connector clamps (7) and the ring

nut (8.2).

2. Remove the actuator from the valve bon-

net.

10 EB 8015 EN

Maintenance – Replacing parts

Ce manuel convient aux modèles suivants

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