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Translation of original instructions

OxygenInstructions and information on how to safely handle devices foroxygen service
Edition January 2024

Sauerstoff!
Oxygen!
Oxygène!

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 forlater reference.
Î If you have any questions about these instructions, contact SAMSON‘s After-sales Service(aftersalesservice@samsongroup.com).

Documents relating to the device, such as the mounting and operating instructions, are available on our website at www.samsongroup.com >Downloads > Documentation.

Definition of signal words! DANGER
Hazardous situations which, if not avoided,
will result in death or serious injury! WARNING
Hazardous situations which, if not avoided,
could result in death or serious injury! NOTICE
Property damage message or malfunction
Note
Additional information
Tip
Recommended action

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Contents

1
1.1
1.2
1.3

Safety instructions and measures....................................................................5
Notes on possible severe personal injury..........................................................9
Notes on possible personal injury..................................................................10
Notes on possible property damage...............................................................11

2
2.1
2.2
2.3

Markings on the device................................................................................12
Nameplate...................................................................................................12
Label for oxygen service................................................................................12
Marking on the packaging............................................................................12

3
3.1
3.2
3.3

Basics..........................................................................................................13
Properties of oxygen.....................................................................................13
Necessary conditions for a fire.......................................................................14
Cleanliness...................................................................................................15

4
4.1
4.2
4.3
4.4

Measures for preparation.............................................................................16
Unpacking...................................................................................................16
Transporting and lifting.................................................................................16
Storage........................................................................................................16
Preparation for installation.............................................................................17

5
5.1
5.2
5.3
5.4

Mounting and start-up..................................................................................18
Installation....................................................................................................19
Additional fittings..........................................................................................20
Quick testing................................................................................................20Start-up........................................................................................................21

6
6.1

Operation....................................................................................................22
Safe working in the plant...............................................................................23

7
7.1
7.2
7.3
7.4
7.5

Servicing.....................................................................................................24
Determining the extent of servicing required....................................................25
Performing service work................................................................................25
Cleaning......................................................................................................26
Returning devices to SAMSON......................................................................26
Ordering spare parts and operating supplies..................................................27

8
8.1
8.2

Troubleshooting...........................................................................................29
Troubleshooting............................................................................................29
Emergency action.........................................................................................29

9
9.1

Decommissioning and removal.....................................................................30
Decommissioning..........................................................................................31

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Contents

10
10.1

Appendix.....................................................................................................31
After-sales service.........................................................................................31

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Safety instructions and measures

1 Safety instructions and measures
Scope of documentation
This manual contains instructions and information that are relevant to the use of SAMSON
devices intended for oxygen service.
The following documents apply in addition to this manual:− Mounting and operating instructions for the purchased SAMSON device, e.g. valve, actuator or valve accessories− Material safety data sheet (MSDS) for oxygen (issued by the oxygen supplier)! WARNING
Risk of personal injury and misuse resulting from the failure to observe the mounting andoperating instructions.
This manual applies to devices for oxygen service in addition to the mounting and operating
instructions for the specific device.
Î Observe the referenced documentation.
Intended use
The SAMSON devices with a label for oxygen service affixed to them (see Chapter 2.2) aredesigned to control the flow of liquid or gaseous oxygen.
Î Only use devices approved for oxygen in oxygen applications.
Î In case of doubt about the suitability for oxygen service, contact SAMSON's After-sales
Service.
The devices are designed to operate under exactly defined conditions (e.g. pressure, temperature). Therefore, operators must ensure that the devices are only used in operating conditions that meet the specifications used for sizing the devices at the ordering stage. In case
operators intend to use the devices in applications or conditions other than those specified,contact SAMSON.
SAMSON does not assume any liability for damage resulting from the failure to use the device 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.

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5

Safety instructions and measures

Reasonably foreseeable misuse
The device 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 accessories connected to the device
Furthermore, the following activities do not comply with the intended use:
− Use of non-original spare parts− Use of spare parts not suitable for oxygen service− Performing service and repair work not described
Qualifications of operating personnel
The device must be mounted, started up, serviced and repaired by fully trained and qualified
personnel only; the accepted industry codes and practices must be observed. According tothis manual, qualified personnel refers to individuals who are able to judge the work they are
assigned to and recognize possible dangers due to their specialized training, their knowledge and experience as well as their knowledge of the applicable standards.
Furthermore, the operating personnel must be specially trained for the correct and safe handling of oxygen. The minimum knowledge required involves:− Knowledge on how fires occur (e.g. fire triangle)− Knowledge on potential ignition sources and mechanisms in the system− Knowledge on flammability of the materials used in the plant and device− Knowledge of the relevant standards commonly used in the process industry e.g. EIGA(European Industrial Gases Association), AIGA (Asia Industrial Gases Association) andCGA (Compressed Gas Association)
SAMSON does not assume any liability for personal injury or property damage caused byuntrained operating personnel.
Tip
All SAMSON staff receives appropriate training before performing any activities in connection with oxygen service. SAMSON's After-sales Service also offers such training courses forcustomers to allow them to learn how to handle devices for oxygen service correctly andsafely.

6

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Safety instructions and measures

Personal protective equipment
To prevent fire or injury, make sure that the personal protective equipment fulfills the following criteria:− Clean and above all free of oil and grease− Cold resistant− Lint-free− Flame retardant! DANGER
Fire risk due to increased concentration of oxygen in the atmosphere.
Flame-retardant protective clothing can also catch fire when the oxygen concentration in the
air is high enough.
Î Observe the information on how a fire starts and on possible ignition sources.
We recommend wearing the following protective equipment when handling oxygen:
Personal protective equipment

Note

Eye protection

Goggles with side shields when performing visual inspections
Fully enclosed goggles when performing service and repair work

Respiratory prot.

In hazardous areas

Hearing protection

When working close to the device

Safety gloves

Lint-free and cold-resistantProtective clothing (e.g. apron)

Lint-free, cold-resistant and flame-retardantÎ Check with the plant operator for details on further protective equipment.
! DANGER
Fire risk due to oxygen-enriched clothing.
Personal protective equipment does not protect clothing and hair against becoming saturated
with oxygen. When taking off oxygen-enriched clothing, the resulting electrostatic discharge
may suffice as an ignition source.
Î Do not wear oxygen-enriched clothing while working.
Î Do not remove oxygen-enriched clothing in the danger zone.
Î Before removing clothing, air them for at least 15 minutes in the open air.

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7

Safety instructions and measures

Safety devices
For oxygen applications, we recommend using oxygen measuring equipment and safety devices which issue a warning when the concentration of oxygen in the atmosphere becomes
too high.
Warning against residual hazards
To avoid personal injury or property damage, operators and operating personnel must prevent hazards that could be caused in the device by the process medium (oxygen) by taking
appropriate precautions. Plant operators and operating personnel must observe all hazard
statements, warnings and caution notes in this manual as well as the mounting and operating instructions of the devices used.
Responsibilities of the operator
Operators are responsible for proper use and compliance with the safety regulations. The
operator is obliged to provide this manual as well as the referenced documents to the operating personnel and to instruct them in proper operation. Furthermore, operators must ensurethat operating personnel or third parties are not exposed to any danger.
We recommend establishing a work permit procedure to regulate entry into the plant and thehazardous area as well as the performance of certain activities (e.g. mounting, start-up, operation, service and repair work). The plant operator is responsible for granting such approvals.
Responsibilities of operating personnel
Operating personnel must read and understand this manual as well as the referenced documents and observe the specified hazard statements, warnings and caution notes. Furthermore, operating personnel must be familiar with the applicable health, safety and accident
prevention regulations especially concerning oxygen service and comply with them (see‘Qualifications of operating personnel’).
Material safety data sheet (MSDS)
Oxygen is classified as a hazardous substance according to the Regulation (EC)No. 1907/2006 (REACH Regulation). Material safety data sheets must be issued for hazardous substances by the supplier (see Article 31 and Annex II in 1907/2006/EC).
Î Observe the instructions in the material safety data sheet (MSDS).
Î If necessary, contact the oxygen supplier to obtain an MSDS.

8

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Safety instructions and measures

1.1 Notes on possible severe personal injury! DANGER
Risk of explosion or fire through the presence of oxygen.
Oxygen is classified as a hazardous substance. A risk of explosion exists for pressurized plants. Oxygen accelerates combustion. Even slightly higher oxygen concentrations lead to rapid and intense combustion.
Î Remove ignition sources.
Î Avoid sparking.
Î Make sure the cleanliness meets the requirements specified in the standards for oxygen service.
Î Avoid oxygen enrichment.
Î Only allow qualified operating personnel to work.
Î Wear personal protective equipment.
Î Observe the instructions in the material safety data sheet (MSDS). If necessary,
contact the oxygen supplier to obtain an MSDS.
Risk of injury due to incorrect handling of oxygen.
Operating personnel must be trained for oxygen service. Unqualified operating personnel expose themselves and others to an increased risk of injury.
Î Operating personnel must be sufficiently trained and be made aware of the hazards occurring in oxygen service.
Î Do not enter the hazardous area without prior permission and without appropriate
training.
Frostbite and severe burn injuries through contact with liquid oxygen.
The temperature of liquid oxygen is –183 °C at atmospheric pressure. Skin contact
with liquid oxygen causes severe frostbite and cold burns (cryogenic burns). Severe
cryogenic burns can be fatal.
Î Do not touch liquid oxygen.
Î Wear cold-resistant safety gloves and protective equipment.

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9

Safety instructions and measures! DANGER
Fire risk due to the use of unsuitable lubricant.
Unsuitable lubricants can react with oxygen and cause a fire.
Î Only use lubricants that have been tested for use with oxygen by a laboratory
nominated by EIGA (European Industrial Gases Association).
Î Only use lubricants approved by SAMSON.
Fire risk due to the use of contaminated tools.
The tools must be cleaned before use in oxygen applications. Particles collecting on
contaminated tools can react with oxygen and cause a fire.
Î Only use clean tools.
Î See associated device documentation for additional notes on possible severe personal injury.

1.2 Notes on possible personal injury! WARNING
Damage to health through inhaling high concentrations of oxygen.
Inhaling high concentrations of oxygen can cause adverse health effects (e.g. dizziness, nausea, impaired vision, hearing defects, impaired balance and unconsciousness). The presence of an oxygen-enriched atmosphere cannot be detected by humansenses.
Î Avoid oxygen enrichment.
Î Leave the oxygen-enriched environment. Move to fresh air.
Î Use oxygen measuring equipment.
Î Wear a respirator for applications with gaseous oxygen.
Î See associated device documentation for additional notes on possible personal injury.

10

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Safety instructions and measures

1.3 Notes on possible property damage! NOTICEÎ See associated device documentation for notes on possible property damage.

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11Markings on the device

2 Markings on the device
2.1 Nameplate
The nameplate includes details on the device
version. Detailed information on the nameplate can be found in the associated device
documentation.

2.2 Label for oxygen service
In addition to the nameplate, control valves
for oxygen service have a label for oxygen
service affixed to them. Which label is used
depends on the version:− Gaseous oxygen: GOX− LOX: liquid oxygen and cold gaseous
oxygen below –30 °C

GOX

1010-5365

LOX

Sauerstoff!
Oxygen!
Oxygène!

p max = 25 bar
t max = 200 °C

Gehäuse-Nenndruckstufe beachten
Observe the nominal pressure rating of the bodyRespecter la pression nominale du corps
Fig. 2: Label for oxygen service includingpressure and temperature specifications

2.3 Marking on the packaging
All components that have been cleaned andpacked by SAMSON for oxygen service
have a label on the packaging (see Fig. 3).

Sauerstoff!
Oxygen!
Oxygène!
Fig. 3: Adhesive label on the packaging

1010-5365
Fig. 1: Labels for gaseous oxygen (GOX) andliquid oxygen (LOX)

If a certain pressure and temperature havebeen specified in the order, the device ismarked with a label for oxygen service
which includes these specifications (seeFig. 2).

12

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Basics

3 Basics
NoteThis chapter outlines the basics of oxygen.
This information does not replace a training
course. SAMSON does not assume any liability for personal injury or property damage
caused by untrained operating personnel.

3.1 Properties of oxygen

oxide of the highest oxidation state are an
exception. Even materials which are regarded to be fireproof can still burn at a sufficiently high pressure and oxygen concentration, e.g. PTFE, silicone and stainless steel.
Inhaling high concentrations of oxygen cancause adverse health effects (e.g. dizziness,
nausea, impaired vision, hearing defects,
impaired balance and unconsciousness).
A risk of asphyxiation exists if the oxygen
concentration in the atmosphere falls below
21 % (w/v).

! WARNING
Risk of injury arising from handling hazardous substances.
Oxygen is classified as a hazardous substance. On delivery, the manufacturer mustensure that the oxygen is specially labeled
and that a material safety data sheet (MSDS)
is provided.
Î Make sure that an MSDS is available. If
necessary, contact the oxygen supplier toobtain an MSDS.
Oxygen is a colorless and odorless gas under normal conditions. Atmospheric air contains approximately 21 % (w/v) oxygen.
At atmospheric pressure, oxygen liquefies at–183 °C and is light blue in color. At–219 °C it crystallizes.
Oxygen is not flammable, but supports andaccelerates combustion. In principle, oxygenis capable of reacting with all organic materials (e.g. dust, oil, wood, even most metals
and their alloys). Noble metals and metal

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13

Basics

3.2 Necessary conditions for a
fire
Generally, three elements are needed to starta fire or explosion:− Flammable material− Oxygen− Ignition source (see ‘Possible ignition
sources’)ntio
ni rce
ig ou
s

co
m
m bu
at st
er ib
ia le
l

A fire or explosion cannot start if one of thethree elements is missing.

oxygenSubstances can ignite spontaneously at
the auto-ignition temperature without anexternal ignition source. Oxygen causes
intense combustion in this case.
3. Effect of pressure
Substances that cannot burn under normal conditions can ignite at sufficiently
high pressure.
4. Flow velocities
High flow velocities can lead to vibrations which, in turn, can act as an ignition source.
5. Contamination
Contamination (e.g. oil or grease) oftools, clothing or components influences
the probability of ignition
Possible ignition sources

Fig. 4: Fire triangle

On handling oxygen, various factors can act
as an ignition source. For example:

Contributory factors− Mechanical stress

1. Oxygen enrichment− Friction between moving and static parts
as well as frictional heating

Even a slight increase in oxygen concentration above 21 % (w/v) affects combustion as follows:− Increasingly intense reaction− Particle impact (especially in cold gaseous oxygen)− Wide spreading of the fire

− Rapid vaporization− Lowers the required ignition energy
and temperature− Electric arcs

− Increases the flame temperature− Mechanical failure of a component

The higher the oxygen concentration is,
the more intense the combustion is.
2. Effect of temperature

14− Hot surfaces− Electrostatic discharge− Surface imperfections− Contamination− Hot work (e.g. welding, cutting, soldering, grinding)

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Basics− Sparking, e.g. through tools being
dropped or oxygen-enriched clothing being opened! DANGER
Risk of explosion or fire through the presence of oxygen.
Lighting a cigarette can ignite a fire or cause
an explosion.
Î Smoking is absolutely forbidden on handling oxygen.

3.3 Cleanliness
It is particularly important to pay attention tocleanliness on handling oxygen. Even thesmallest amount of contamination can act as
an ignition source and cause a fire:− Dirt, deposits, particles, hydrocarbons,cleaning agent residues− Unsuitable lubricant− Contaminated lubricant, tools or cloths− Particles (originating from gasket breakdown, valve friction, abrasion etc.)− Packaging material
Î Make sure the cleanliness meets the requirements specified in the standards foroxygen service.
Î Observe notes on cleaning (see Chapter 7.3).

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15

Measures for preparation

4 Measures for preparation
After receiving the shipment, proceed as follows:
1. Check the scope of delivery. Compare
the shipment received with the deliverynote.
2. Check the shipment for transportation
damage. Report any damage to
SAMSON and the forwarding agent(refer to delivery note).
3. Check the packaging for damage.
Note
In case the packaging is damaged, the components contained in the packaging must be
cleaned, dried and packed again. Contact
our after-sales service concerning recleaning.
4. Check the delivery for contamination (visual inspection without opening the
packaging).
5. The delivery must be marked with a label
for oxygen service (see Chapter 2.3). If it
is not labeled accordingly, the device
must not be used for oxygen service.
Contact our after-sales service.

4.1 Unpacking
Note
All components intended for oxygen service
have been carefully cleaned and packed by

16

SAMSON to meet the requirements of allcommon standards.
− Unpack components cleaned for oxygen
service only in areas intended for this purpose.
− Do not remove the packaging from thecomponents cleaned for oxygen service
until immediately before installation.
Before installing the device, proceed as follows:
1. Remove the packaging from the device.
2. Dispose of the packaging in accordancewith the valid regulations.

4.2 Transporting and lifting
Î Make sure that the packaging is notdamaged during transportation andhoisting.
Note
Additional instructions on transportation andlifting can be found in the associated device
documentation or are available from our after-sales service on request.

4.3 Storage
We recommend the following for storage ofcomponents and devices intended for oxygen service:− During long storage periods, checkregularly that the labeling for oxygen
service remains legible and the
packaging intact. Renew any labeling

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Measures for preparationthat has become illegible. When the
packaging is damaged, the device may
possibly be contaminated. Contact our
after-sales service.
− Store components intended for oxygen
service in a separate area which ismarked accordingly.

Î Clean all tools. The tools must be free ofgrease, oil and hydrocarbons. The same
applies to the immediate work environment (workbench etc.). Cover up theworking area with a lint-free cloth to prevent the tools and components from being contaminated.

− Store components in a dry atmosphere.

Î Make sure that clothing and safety gloves
are clean.

Note
Additional instructions on storage can befound in the associated device documentation or are available from our after-sales service on request.

Î Blow out the pipeline section with clean,dry, oil-free compressed air.

4.4 Preparation for installation

Î Check the lubricant to ensure it is compatible with oxygen.

We recommend performing all preparation
work on the device in an area specially intended for oxygen service.
Proceed as follows:Î Completely remove any drying agent (ifused).
Î Check the material and cleanliness ofgaskets.

Note
See associated device documentation forfurther preparation.

Î Perform a visual inspection of the device,e.g. at the valve inlet and outlet as well
as at all accessible points. Make surethat all components have been cleaned.
Contact our after-sales service when
components are contaminated.
Î Make sure that the packaging has notbeen damaged during transport andstorage (visual inspection). When the
packaging is damaged, the device may
possibly be contaminated. Contact our
after-sales service before using the device.

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Mounting and start-up

5 Mounting and start-up! DANGER
Risk of explosion or fire through the presence of oxygen.
Oxygen is classified as a hazardous substance. A risk of explosion exists for pressurized plants. Oxygen accelerates combustion.
Even slightly higher oxygen concentrations
lead to rapid and intense combustion.
Î Remove ignition sources.
Î Avoid sparking.
Î Make sure the cleanliness meets the requirements specified in the standards foroxygen service.
Î Avoid oxygen enrichment.
Î Only allow qualified operating personnel
to work.
Î Wear personal protective equipment.
Î Observe the instructions in the material
safety data sheet (MSDS). If necessary,
contact the oxygen supplier to obtain an
MSDS.
! DANGER
Frostbite and severe burn injuries throughcontact with liquid oxygen.
The temperature of liquid oxygen is –183 °C
at atmospheric pressure. Skin contact withliquid oxygen causes severe frostbite andcold burns (cryogenic burns). Severe cryogenic burns can be fatal.
Î Do not touch liquid oxygen.
Î Wear cold-resistant safety gloves andprotective equipment.

18! DANGER
Fire risk due to the use of unsuitable lubricant.
Unsuitable lubricants can react with oxygenand cause a fire.
Î Only use lubricants that have been tested
for use with oxygen by a laboratory
nominated by EIGA (European Industrial
Gases Association).
Î Only use lubricants approved by
SAMSON.
! DANGER
Fire risk due to the use of contaminatedtools.
The tools must be cleaned before use in oxygen applications. Particles collecting on contaminated tools can react with oxygen andcause a fire.
Î Only use clean tools.
! WARNING
Damage to health through inhaling highconcentrations of oxygen.
Inhaling high concentrations of oxygen cancause adverse health effects (e.g. dizziness,
nausea, impaired vision, hearing defects,
impaired balance and unconsciousness). The
presence of an oxygen-enriched atmospherecannot be detected by human senses.
Î Avoid oxygen enrichment.
Î Leave the oxygen-enriched environment.
Move to fresh air.
Î Use oxygen measuring equipment.

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Mounting and start-up

Î Wear a respirator for applications withgaseous oxygen.

occur (see subsection 4.6.2 of EIGA Doc 13/12).
Mounting orientation! WARNING
Risk of injury due to incorrect handling ofoxygen.
Operating personnel must be trained for oxygen service. Unqualified operating personnel expose themselves and others to an increased risk of injury.
Î Operating personnel must be sufficiently
trained and be made aware of the hazards occurring in oxygen service.
Î Do not enter the hazardous area without
prior permission and without appropriate training.
General conditions
Î Wear clean personal protective equipment that is suitable for the purpose (seeChapter 1).
Î Only use clean tools.
Î Do not allow the device and the components to become contaminated. Pay attention to cleanliness.

5.1 Installation
Î On installation, make sure that thecleaned components do not becomecontaminated. Contact our after-sales
service concerning the cleaning ofcontaminated components.
Î On installation, make sure that no vibrations or forces from external sources can

H 01 ENÎ Refer to the mounting and operating instructions of the device for details on themounting position.
Procedure for mounting and start-up
1. Shut off the oxygen supply. Close any
upstream shut-off valves in the pipeline
while the valve is being installed.
2. Depressurize the plant.
3. Do not enter the danger zone until theoxygen concentration in the atmosphereis safe. Use oxygen measuring equipment.
4. Blow out the pipeline section with clean,dry, oil-free compressed air. Alternatively, use nitrogen or a noble gas to blowout the pipe.
5. Remove any protective caps from thevalve ports before installing the valve.
6. Install the device. Read ‘Notes on performing hot work’.
7. After installation, blow out the device
and adjoining pipeline to remove any
weld spatter or other residue. Observe
notes on cleaning (see Chapter 7.3).
8. Depending on the field of application,
allow the device to cool down or warm
up to reach ambient temperature before
start up.
9. Check the device to ensure it functions
properly (see Chapter 5.3).

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Mounting and start-up

10. Put the device into operation (see Chapter 5.4).
Notes on performing hot work
Hot work (e.g. welding, soldering, cutting,
grinding) can be a potential ignition source.
Î Do not perform hot work without priorwritten permission (hot work permit).
Î Make sure the area is sufficiently ventilated during welding work.
Î Use suitable welding techniques.
! DANGER
Risk of explosion due to incorrect performance of hot work.
Î Hot work is to be performed only by staff
trained for this purpose.

5.2 Additional fittings
Note
The listed additional fittings arerecommended by SAMSON. The plant
operator is responsible for implementationand installation.
Shut-off valves
We recommend installing a hand-operated
shut-off valve both upstream and downstream of the device. The shut-off valves ensure that the entire plant does not need to be
shut down for service and repair work on thedevice.

20

Bypass
A bypass can be installed to prevent highflow velocities, rapid pressurization and highmechanical loads. The bypass must be installed in such a way that vibrations are kept
to a minimum.
Ventilation
Sufficient ventilation (exchange of air) must
be ensured to prevent oxygen enrichment in
the plant.
Noise reduction
Information on the selection of suitable measures to reduce noise emissions can be foundin the associated device documentation orcontact our after-sales service.
Fire wall
A fire wall can be added to additionallysafeguard the danger zone.

5.3 Quick testing
Additional instructions on how to briefly test
the device can be found in the associateddevice documentation. Additionally observe
the following instructions on performing thetests.
Pressure test
Î Perform the pressure test using clean,dry, oil-free compressed air or nitrogen.
LeakageÎ Perform the leak test using clean, dry,oil-free compressed air or nitrogen.

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Mounting and start-up

5.4 Start-up
We recommend that the operating personnel
leave the plant during start-up.
The applicable industry standards for cleaning procedures (e.g. EIGA) must be observed. Suitable measures include:Î Before starting up the plant, blow out theplant with clean, dry, oil-free air to remove any particles or dirt. Alternatively,
nitrogen or a noble gas can be used forblowing out the plant.
Î Observe design limits.
Î Make sure that the process medium remains free of particles while the plant isrunning.
Î Pressurize the plant. Pressure surges(rapid pressurization) in the plant mustbe ruled out (see EIGA Doc 13/12, Appendix B).
Î Open the oxygen supply. Slowly open
the upstream shut-off valve in the pipeline, if installed.
! NOTICE
Risk of valve damage due to a suddenpressure increase and resulting high flow
velocities.
Î Slowly open the shut-off valve in thepipeline during start-up.

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21

Operation

6 Operation! DANGER
Risk of explosion or fire through the presence of oxygen.
Oxygen is classified as a hazardous substance. A risk of explosion exists for pressurized plants. Oxygen accelerates combustion.
Even slightly higher oxygen concentrations
lead to rapid and intense combustion.
Î Remove ignition sources.
Î Avoid sparking.
Î Make sure the cleanliness meets the requirements specified in the standards foroxygen service.
Î Avoid oxygen enrichment.
Î Only allow qualified operating personnel
to work.
Î Wear personal protective equipment.
Î Observe the instructions in the material
safety data sheet (MSDS). If necessary,
contact the oxygen supplier to obtain an
MSDS.
! DANGER
Frostbite and severe burn injuries throughcontact with liquid oxygen.
The temperature of liquid oxygen is –183 °C
at atmospheric pressure. Skin contact withliquid oxygen causes severe frostbite andcold burns (cryogenic burns). Severe cryogenic burns can be fatal.
Î Do not touch liquid oxygen.
Î Wear cold-resistant safety gloves andprotective equipment.

22! WARNING
Damage to health through inhaling highconcentrations of oxygen.
Inhaling high concentrations of oxygen cancause adverse health effects (e.g. dizziness,
nausea, impaired vision, hearing defects,
impaired balance and unconsciousness). The
presence of an oxygen-enriched atmospherecannot be detected by human senses.
Î Avoid oxygen enrichment.
Î Leave the oxygen-enriched environment.
Move to fresh air.
Î Use oxygen measuring equipment.
Î Wear a respirator for applications withgaseous oxygen.
! WARNING
Risk of injury due to incorrect handling ofoxygen.
Operating personnel must be trained for oxygen service. Unqualified operating personnel expose themselves and others to an increased risk of injury.
Î Operating personnel must be sufficiently
trained and be made aware of the hazards occurring in oxygen service.
Î Do not enter the hazardous area without
prior permission and without appropriate training.

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Operation

6.1 Safe working in the plant
Note
The plant operator is responsible for establishing and implementing suitable safetymeasures in the plant.
We recommend the following safety precautions to protect the operating personnel whileworking in the danger zone 1) during operation:
Ventilation
Sufficient ventilation must be ensured to prevent oxygen enrichment in the plant.
Oxygen monitor and alarm equipment
The equipment triggers an alarm when theconcentration of oxygen exceeds a limit andto ensure that the air is regularly exchanged.

Entry permit
Entry only for trained operating personnel
with written permission (individual authorization).
Absence of particles
Î Make sure that the process medium remains free of particles while the plant isrunning.
Forces and vibrations from external sourcesÎ On installation, make sure that no vibrations or forces from external sources canoccur (see subsection 4.6.2 of EIGA Doc 13/12).
Pressure surges
Î Pressure surges (rapid pressurization) in
the plant must be ruled out (see EIGA Doc 13/12, Appendix B).

Warning signs
We recommend putting up at least the following warning signs in the plant:− No open flames− No smoking− Oxygen warning− Entry only with portable oxygen
measuring equipment− Entry only for trained/authorized
personnel

1)

According to the Technical Rules for Hazardous Substances TRGS 407 issued by the German
Federal Institute for Occupational Safety and Health (BAUA), the danger zone is the area in which adangerous gas concentration cannot be ruled out due to the local operating conditions.

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23

Servicing

7 Servicing! DANGER
Risk of explosion or fire through the presence of oxygen.
Oxygen is classified as a hazardous substance. A risk of explosion exists for pressurized plants. Oxygen accelerates combustion.
Even slightly higher oxygen concentrations
lead to rapid and intense combustion.
Î Remove ignition sources.
Î Avoid sparking.
Î Make sure the cleanliness meets the requirements specified in the standards foroxygen service.
Î Avoid oxygen enrichment.
Î Only allow qualified operating personnel
to work.
Î Wear personal protective equipment.
Î Observe the instructions in the material
safety data sheet (MSDS). If necessary,
contact the oxygen supplier to obtain an
MSDS.
! DANGER
Frostbite and severe burn injuries throughcontact with liquid oxygen.
The temperature of liquid oxygen is –183 °C
at atmospheric pressure. Skin contact withliquid oxygen causes severe frostbite andcold burns (cryogenic burns). Severe cryogenic burns can be fatal.
Î Do not touch liquid oxygen.
Î Wear cold-resistant safety gloves andprotective equipment.

24! WARNING
Damage to health through inhaling highconcentrations of oxygen.
Inhaling high concentrations of oxygen cancause adverse health effects (e.g. dizziness,
nausea, impaired vision, hearing defects,
impaired balance and unconsciousness). The
presence of an oxygen-enriched atmospherecannot be detected by human senses.
Î Avoid oxygen enrichment.
Î Leave the oxygen-enriched environment.
Move to fresh air.
Î Use oxygen measuring equipment.
Î Wear a respirator for applications withgaseous oxygen.
! WARNING
Fire risk due to the use of unsuitable lubricant.
Unsuitable lubricants can react with oxygenand cause a fire.
Î Only use lubricants that have been tested
for use with oxygen by a laboratory
nominated by EIGA (European Industrial
Gases Association).
Î Only use lubricants approved by
SAMSON.
! WARNING
Fire risk due to the use of contaminatedtools.
The tools must be cleaned before use in oxygen applications. Particles collecting on contaminated tools can react with oxygen andcause a fire.

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Servicing

Î Only use clean tools.
! WARNING
Risk of injury due to incorrect handling ofoxygen.
Operating personnel must be trained for oxygen service. Unqualified operating personnel expose themselves and others to an increased risk of injury.
Î Operating personnel must be sufficiently
trained and be made aware of the hazards occurring in oxygen service.
Î Do not enter the hazardous area without
prior permission and without appropriate training.

7.1 Determining the extent ofservicing required
We recommend performing service or repair
work at the latest under the following circumstances:− When the plug stem surface is scratchedor cracked.
Note
Scratches and cracks can impair the sealingability and, as a result, increase the risk ofcontamination.
− When the valve leaks at the packing or
body gasket− In the event of applied lubricant leaks
from the actuator

H 01 EN− In the event of the icing up of susceptible
components (e.g. valve accessories andactuator)
Depending on the operating conditions,check the valve at certain intervals to prevent
possible failure due to wear before it can occur.
Note
The plant operator is responsible for drawing up an inspection and test plan for theplant. Our after-sales service can support
you in drawing up an inspection and test
plan for your plant to perform predictive service work.

7.2 Performing service work
Note
Do not perform any service work without
prior written permission from the plant operator.
1. Shut off the oxygen supply. Close any
upstream shut-off valves in the pipeline
while the valve is being installed.
2. Depressurize the plant.
3. Do not enter the danger zone until theoxygen concentration in the atmosphereis safe. Use oxygen measuring equipment.
4. Blow out the pipeline section with clean,dry, oil-free compressed air. Alternatively, use nitrogen or a noble gas to blowout the pipe.

25Servicing

5. Replace parts subject to wear. Detailed
information on replacing parts subject towear can be found in the associated device documentation.
6. After performing service work, blow out
the device and adjoining pipeline to remove any weld spatter or other residue.
Observe notes on cleaning (see Chapter 7.3).

7.4 Returning devices to
SAMSON
Defective or contaminated devices can be returned to SAMSON for repair or cleaning.
Proceed as follows to return devices to
SAMSON:
1. Put the device out of operation (seeChapter 9).

7. Check the device to ensure it functions
properly (see Chapter 5.3).

2. Decontaminate the device. Remove any
residual process medium.

8. Put the plant into operation. See Chapter 5.4.

3. Exceptions apply concerning somespecial device models
u www.samsongroup.com > Service >After-sales Service > Returning goods.

7.3 Cleaning
The device may become contaminatedduring operation or installation and service
work. Contamination can act as an ignition
source and cause a fire. The applicable industry standards for cleaning procedures(e.g. EIGA) must be observed.
Î Contact our after-sales service concerning the cleaning of the device.
Î To remove possible contamination, blowout the pipeline section with clean, dry,oil-free compressed air. Alternatively,
nitrogen or a noble gas can be used forblowing out the plant.

4. Send an e-mailu retouren@samsongroup.com to register the return shipment including the following information:– Type– Article number– Configuration ID– Original order– Completed Declaration on
Contamination, which can be
downloaded from our website atu www.samsongroup.com > Service> After-sales Service > Returning
goods.
After checking your registration, we will
send you a return merchandise authorization (RMA).

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Servicing

5. Attach the RMA (together with the Declaration on Decontamination) to the outside of your shipment so that the documents are clearly visible.

Î The spare parts have been cleaned foroxygen service. Contact our after-sales
service concerning recleaning of contaminated components.

6. Send the shipment to the address givenon the RMA.

Î Store spare parts for oxygen service separately from spare parts for normal use.

Note
Further information on returned devices andhow they are handled can be found at
u www.samsongroup.com > Service > Aftersales Service.

Note
Spare parts lists for SAMSON devices canbe found at u www.samsongroup.com >Downloads > Documentation.
Lubricant

7.5 Ordering spare parts andoperating supplies
Contact your nearest SAMSON subsidiaryor SAMSON's After-sales Service for information on spare parts, lubricants and tools.
Spare parts
Only use original spare parts by SAMSON,
which comply with the original specifications.

Î Only use lubricants that have been tested
for use with oxygen by a laboratory
nominated by EIGA (European Industrial
Gases Association).
Î Only use lubricants approved by
SAMSON.
Î Make sure that any residual lubricant(e.g. after servicing the actuator) is completely removed.

Do not use spare parts that are not designed
specially for oxygen service.
When handling spare parts, make sure thefollowing conditions are met:
Î Make sure that supplied spare parts arecorrectly packed and labeled for oxygen
service.
Î Check the cleanliness of supplied spareparts (visual inspection without removing
the parts from the packaging).
Î Do not remove the packaging until immediately before installation.

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27

Servicing

Tools
Suitable tools sets that have been cleaned foroxygen service can be ordered from our after-sales service. Non-sparking tools are alsoavailable.
! WARNING
Contamination of the device and plant due
to contaminated tools.
The tools must be cleaned before use in oxygen applications. Particles collecting on contaminated tools can react with oxygen.
Î Only use clean tools.
Tip
Lint-free oxygen gloves can be ordered from
our after-sales service for handling devices
intended for oxygen service.

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Troubleshooting

8 Troubleshooting
8.1 Troubleshooting! DANGER
Risk of explosion or fire through the presence of oxygen.
Î Do not perform corrective action while the process is running.
Î Read instructions in Chapter 7.
Malfunction

Possible reasons

Recommended action

Leakage to the atmosphere (withliquid oxygen)

Gaskets or pipelines leaking.

Renew gaskets. See associateddevice documentation.

Leakage at the flanges

Flanged joint not tight.

Tighten flange joint manually.
Observe tightening torques.
Only use manual tools.

Leakage at the screw fittings

Screw fittings loosened.

Tighten screw fittings manually.

Actuator or valve accessories
iced up.

Bellows or circulation inhibitor
leaking.

Contact our after-sales service.
Use hot air, water or steam tomelt away ice. Make sure thatthe medium used is free oil andgrease.

Î See associated device documentation for further troubleshooting.

8.2 Emergency action
Plant operators are responsible for emergency action to be taken in the plant.

3. To put the back into service, proceed as
described in Chapter 5.3.

In the event of a device malfunction:
1. Shut off oxygen supply if it is safe to doso.
2. After the risk has been eliminated, checkthe device for damage. Rectify the fault.
Contact SAMSON's After-sales Service.

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29

Decommissioning and removal

9 Decommissioning andremoval! DANGER
Risk of explosion or fire through the presence of oxygen.
Oxygen accelerates combustion. Evenslightly higher oxygen concentrations lead to
rapid combustion.
Î Make sure the cleanliness meets the requirements specified in the standards foroxygen service.
Î Avoid sparking.
Î Wear personal protective equipment.
Î Observe the information on how a firestarts and on possible ignition sources.

impaired balance and unconsciousness). The
presence of an oxygen-enriched atmospherecannot be detected by human senses.
Î Avoid oxygen enrichment.
Î Leave the oxygen-enriched environment.
Move to fresh air.
Î Use oxygen measuring equipment.
Î Wear a respirator for applications withgaseous oxygen.
! WARNING
Contamination of the device and plant due
to contaminated tools.
The tools must be cleaned before use in oxygen applications. Particles collecting on contaminated tools can react with oxygen.
Î Only use clean tools.

! DANGER
Frostbite and severe burn injuries throughcontact with liquid oxygen.
The temperature of liquid oxygen is –183 °C
at atmospheric pressure. Skin contact withliquid oxygen causes severe frostbite andcold burns (cryogenic burns). Severe cryogenic burns can be fatal.
Î Do not touch liquid oxygen.
Î Wear cold-resistant safety gloves andprotective equipment.
! WARNING
Damage to health through inhaling highconcentrations of oxygen.
Inhaling high concentrations of oxygen cancause adverse health effects (e.g. dizziness,
nausea, impaired vision, hearing defects,

30

H 01 EN

Appendix! WARNING
Risk of injury due to incorrect handling ofoxygen.
Operating personnel must be trained for oxygen service. Unqualified operating personnel expose themselves and others to an increased risk of injury.
Î Operating personnel must be sufficiently
trained and be made aware of the hazards occurring in oxygen service.
Î Do not enter the hazardous area without
prior permission and without appropriate training.

9.1 Decommissioning
1. Shut off the oxygen supply.
2. Depressurize the plant.
3. Do not enter the danger zone until theoxygen concentration in the atmosphereis safe. Use oxygen measuring equipment.
4. Seal the pipeline section with blind flanges.
5. Blow out the pipeline section with clean,dry, oil-free compressed air. Alternatively, use nitrogen or a noble gas to blowout the pipe.

10 Appendix
10.1 After-sales service
Contact our after-sales service for support
concerning service, repair and cleaning
work or when malfunctions or defects arise.
E-mail contact
You can reach our after-sales service ataftersalesservice@samsongroup.com.
Addresses of SAMSON AG and its subsidiaries
The addresses of SAMSON AG, its subsidiaries, representatives and service facilities
worldwide can be found on our website(www.samsongroup.com) or in all SAMSON
product catalogs.
Required specifications
Please submit the following details:− Order number and position number inthe order− Type, model number and device version− Installation drawing− See associated device documentation forfurther information.

6. Detailed information on the removal anddecommissioning of devices can befound in the associated device documentation.

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31

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

2024-01-25 · English

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