Samson 3251 Manual de servicio

Translation of original instructions

EB 8052-1 EN

Type3251 Valve for molten salt service · ANSI version

In combination with an actuator,

e.g. a SAMSON Type3271 or Type3277 Pneumatic Actuator

Edition August 2016

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.

ÎFor the safe and proper use of these instructions, read them carefully and keep them for

later reference.

ÎIf you have any questions about these instructions, contact SAMSON‘s After-sales Service

Department (aftersalesser[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.

Denition 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

2 EB 8052-1 EN

Contents

EB 8052-1 EN 3

1 Safety instructions and measures ...................................................................5

1.1 Notes on possible severe personal injury .........................................................8

1.2 Notes on possible personal injury ...................................................................9

1.3 Notes on possible property damage..............................................................10

2 Markings on the control valve......................................................................12

2.1 Valve nameplate ..........................................................................................12

2.2 Actuator nameplate......................................................................................13

2.3 Material number..........................................................................................13

3 Design and principle of operation ................................................................14

3.1 Fail-safe positions ........................................................................................14

3.2 Versions ......................................................................................................16

3.3 Technical data .............................................................................................17

4 Measures for preparation............................................................................24

4.1 Unpacking ..................................................................................................24

4.2 Transporting and lifting ................................................................................24

4.2.1 Transporting ................................................................................................25

4.2.2 Lifting..........................................................................................................25

4.3 Storage.......................................................................................................28

4.4 Preparation for installation............................................................................29

5 Mounting and start-up.................................................................................30

5.1 Mounting the actuator onto the valve.............................................................30

5.2 Installing the valve into the pipeline ...............................................................31

5.2.1 Checking the installation conditions...............................................................31

5.2.2 Additional ttings.........................................................................................33

5.2.3 Installing the control valve.............................................................................34

5.3 Conguring the temperature control...............................................................34

5.3.1 Determining the temperature limits ................................................................35

5.3.2 Calculating the required heating power .........................................................35

5.3.3 Conguring the temperature sensor ...............................................................35

5.3.4 Conguring the electric trace heating.............................................................35

5.4 Quick check ................................................................................................36

Contents

4 EB 8052-1 EN

6 Operation...................................................................................................38

6.1 Working in manual mode.............................................................................39

7 Servicing.....................................................................................................40

7.1 Inspection intervals.......................................................................................41

7.2 Replacing the gasket ....................................................................................43

7.2.1 Standard version..........................................................................................43

7.2.2 Version with bellows seal..............................................................................43

7.3 Replacing the packing..................................................................................45

7.4 Replacing the seat and plug..........................................................................47

7.5 Cleaning the pipelines..................................................................................48

7.6 Preparation for return shipment.....................................................................49

7.7 Ordering spare parts and operating supplies .................................................49

8 Malfunctions ...............................................................................................50

8.1 Troubleshooting ...........................................................................................50

8.2 Emergency action ........................................................................................51

9 Decommissioning and disassembly ..............................................................52

9.1 Decommissioning.........................................................................................53

9.2 Removing the valve from the pipeline.............................................................53

9.3 Removing the actuator from the valve ............................................................54

9.4 Disposal......................................................................................................54

10 Appendix....................................................................................................54

10.1 After-sales service........................................................................................54

10.2 Certicates ..................................................................................................54

10.3 Spare parts .................................................................................................56

EB 8052-1 EN 5

Safety instructions and measures

1 Safety instructions and measures

Intended use

The SAMSON Type3251 Globe Valve in combination with an actuator (e.g. Type3271 or

Type3277 Pneumatic Actuator) is designed to regulate the ow rate of molten salt. The valve

with its actuator is designed to operate under exactly dened conditions (e.g. operating pres-

sure, process medium, temperature). Therefore, operators must ensure that the control valve is

only used in applications that meet the specications used for sizing the valve at the ordering

stage. In case operators intend to use the control valve in other applications or conditions

than specied, SAMSON must be contacted.

SAMSON does not assume any liability for damage resulting from the failure to use the

valve for its intended purpose or for damage caused by external forces or any other external

factors.

ÎRefer to the technical data and nameplate for limits and elds of application as well as

possible uses.

Reasonably foreseeable misuse

The control valve is not suitable for the following applications:

−Use outside the limits dened during sizing and in the technical data

−Use outside the limits dened 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

Qualications of operating personnel

The control valve must be mounted, started up, serviced, and repaired by fully trained and

qualied 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 8052-1 EN

Safety instructions and measures

Personal protective equipment

We recommend wearing the following protective equipment when handling molten salt:

−Wear protective clothing, in particular safety gloves, a respirator, and eyewear.

−Wear hearing protection when working near the valve.

ÎCheck with the plant operator for details on further protective equipment.

Revisions and other modications

Revisions, conversions or other modications to 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 devices

Upon supply air or control signal failure, the valve moves to its fail-safe position (see sec-

tion3.1). The fail-safe action corresponds with the direction of action. The fail-safe action of

SAMSON actuators is specied on the actuator nameplate (see actuator documentation).

Warning against residual hazards

To 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.

Responsibilities of the operator

The 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, operators must ensure that operating personnel or third persons are not ex-

posed to any danger.

Responsibilities of operating personnel

Operating personnel must read and understand these mounting and operating instructions as

well as the referenced documents and observe the hazard statements, warning and caution

notes specied in them. Furthermore, the operating personnel must be familiar with the ap-

plicable health, safety and accident prevention regulations and comply with them.

EB 8052-1 EN 7

Safety instructions and measures

Referenced standards and regulations

The control valves comply with the requirements of the European Pressure Equipment Direc-

tive 2014/68/EU. Valves with a CE marking have a declaration of conformity, which in-

cludes information about the applied conformity assessment procedure. This 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.

ÎFor connection to the equipotential bonding system, observe the requirements specied in

section 6.4 of EN60079-14 (VDE0165 Part 1).

Referenced documentation

The following documents apply in addition to these mounting and operating instructions:

−Mounting and operating instructions for mounted actuator, e.g. uEB8310-X for

SAMSON Type3271 and Type3277 Actuators

−Mounting and operating instructions for mounted valve accessories (temperature sensor,

positioner, solenoid valve, etc.)

−Documentation for devices by other manufacturers (e.g. for electric trace heating)

−uWA0029 for tools and tightening torques

8 EB 8052-1 EN

Safety instructions and measures

1.1 Notes on possible severe personal injury

DANGER

Risk of bursting in pressure equipment.

Control valves and pipelines are pressure equipment. Improper opening can lead to

valve components bursting.

ÎBefore starting any work on the control valve, depressurize all plant sections

concerned as well as the valve.

ÎDrain the process medium from all the plant sections concerned and from the valve.

ÎWear personal protective equipment.

Risk of burn injuries due to hot components and pipelines.

Components and pipelines reach temperatures above 300°C (570°F) while the plant is

running. Risk of severe burn injuries if touched.

ÎPrior to performing any work on the valve, allow components and pipelines to cool

down.

ÎWear protective clothing and safety gloves.

Risk of burn injuries from molten salt.

Molten salt reaches very high temperatures of over 200°C (392°F) and leads to severe

burn injuries if touched.

ÎDo not touch molten salt.

ÎWear protective clothing and safety gloves when handling molten salt.

Risk of electric shock.

The following applies when using electric trace heating or other electric components to

heat the valve components:

ÎOnly allow properly trained and instructed operating personnel to perform work on

the mounted device.

ÎObserve the safety instructions in the associated documentation.

EB 8052-1 EN 9

Safety instructions and measures

1.2 Notes on possible personal injury

WARNING

Fire risk due to molten salt.

Individual elements in molten salt (both in crystallized and liqueed state) can acceler-

ate combustion or ignite on coming into contact with certain substances (e.g. graphite).

ÎDo not allow molten salt to come into contact with ammable substances.

Risk of poisoning from molten salt vapors.

Molten salt in the liqueed state produces vapors that are toxic.

ÎDo not inhale molten salt vapors.

ÎMake sure the area is sufciently ventilated.

ÎWear a respirator.

Crush hazard arising from moving parts.

The control valve contains moving parts (actuator and plug stems), which can injure

hands or ngers if inserted into the valve.

ÎDo not insert hands or nger into the yoke while the valve is in operation.

ÎWhile working on the control valve, disconnect and lock the pneumatic air supply as

well as the control signal.

Risk of personal injury when the actuator vents.

While the valve is operating, the actuator may vent during closed-loop control or when

the valve opens or closes.

ÎInstall the control valve in such a way that the actuator does not vent at eye level.

ÎUse suitable silencers and vent plugs.

ÎWear eye protection when working in close proximity to the control valve.

Risk of personal injury due to preloaded springs.

Valves in combination with pneumatic actuators with preloaded springs are under ten-

sion. These control valves with SAMSON pneumatic actuators can be identied by the

long bolts protruding from the bottom of the actuator.

ÎBefore starting any work on the actuator, relieve the compression from the preload-

ed springs (see associated actuator documentation).

10 EB 8052-1 EN

Safety instructions and measures

WARNING

Risk of personal injury due to residual process medium in the valve.

While working on the valve, residual process medium can escape and may lead to per-

sonal injury, e.g. burns.

ÎIf possible, drain the process medium from all the plant sections concerned and from

the valve.

ÎWear protective clothing, safety gloves, and eyewear.

1.3 Notes on possible property damage

NOTICE

Risk of damage to the valve and pipelines due to the process medium crystallizing.

The molten salt crystallizes when its temperature falls below the salt's melting point. The

crystallized medium accumulates in the valve and pipelines causing them to become

blocked. The bellows seal is damaged as a result.

ÎObserve the temperature limits of the process medium. See section5.3.1.

ÎOnly stroke the valve with bellows seal when the process medium is in the liqueed

state.

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.

ÎFlush the pipelines before start-up.

ÎObserve the maximum permissible pressure for valve and plant.

Risk of leakage and valve damage due to excessively high or low tightening torques.

Observe the specied 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.

ÎObserve the specied tightening torques (uWA0029).

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