GE VARIVENT S Series User manual

Hygienic valves
GEA VARIVENT® control valve type S
Operating instruction (Translation from the original language)
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COPYRIGHT
These Operating Instructions are the English translation of the original operating
instructions in the sense of the EU Machinery Directive. This document is
protected by copyright. All rights reserved. The document may not, in whole or in
part, be copied, reproduced, translated or reduced to an electronic medium of
machine-readable form without the express permission of GEA Tuchenhagen
GmbH.
LEGAL NOTICE
Word marks
The designations VARIVENT® and T.VIS® are protected trademarks of GEA
Tuchenhagen GmbH.
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TABLE OF CONTENTS
1 General Information 5
1.1 Information on the Document 5
1.1.1 Binding Character of These Operating Instructions 5
1.1.2 Notes on the Illustrations 5
1.1.3 Symbols and Highlighting 5
1.2 Manufacturer address 6
1.3 Contact 6
1.4 EC Declaration of Conformity 7
2 Safety 10
2.1 Intended use 10
2.1.1 Requirements for operation 10
2.1.2 Pressure equipment directive 10
2.1.3 ATEX directive 10
2.1.4 Improper operating conditions 10
2.2 Operator’s Duty of Care 11
2.3 Subsequent changes 12
2.4 General safety instructions and dangers 12
2.4.1 Principles for safe operation 12
2.4.2 Environmental Protection 12
2.4.3 Electrical Equipment 13
2.5 Supplementary Regulations 13
2.6 Qualification of personnel 13
2.7 Safety equipment 15
2.7.1 Signage 15
2.8 Residual dangers 15
2.9 Danger zones 16
3 Description 17
3.1 Design 17
3.2 Functional description 19
3.2.1 Spring-to-close actuator (Z) 19
3.2.2 Spring-to-open actuator (A) 19
4 Transport and storage 20
4.1 Storage conditions 20
4.2 Transport 20
4.2.1 Scope of supply 20
5 Technical data 21
5.1 Type plate 21
5.2 Technical data 22
5.3 Seat leakage according to DIN EN 60534-4 23
5.4 Resistance of Sealing Materials 24
5.5 Pipe ends - General table of measurements 25
5.6 Tools 27
5.7 Auxiliary equipment 28
5.8 Lubricants 28
5.9 Weights 29
6 Assembly and installation 30
6.1 Safety instructions 30
6.2 Notes on installation 30
6.3 Valve with Detachable Pipe Connection Elements 30
6.4 Valve with Welded Ends 31
6.5 Pneumatic connections 32
6.6 Electrical connections 32
7 Start-up 34
7.1 Safety instructions 34
7.2 Notes on commissioning 34
8 Operation and control 35
8.1 Safety instructions 35
9 Cleaning 36
9.1 Cleaning 36
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9.1.1 Cleaning Process Examples 36
9.1.2 Cleaning effect 36
9.2 Passivation 37
10 Maintenance 38
10.1 Safety instructions 38
10.2 Inspections 39
10.2.1 Product contact seals 39
10.2.2 Pneumatic connections 39
10.2.3 Electrical connections 39
10.3 Maintenance intervals 39
10.4 Prior to disassembly 40
10.5 Disassembling the Valve 40
10.5.1 Disassembling Valve N 40
10.5.2 Disassembling Valves W + X 42
10.5.3 Disassembling the 3-Stage Seat / Double Stem Guide 47
10.5.4 Dismantling the Actuator Back Plate 49
10.6 Maintenance 51
10.6.1 Cleaning the Valve 51
10.6.2 Replacing Seals 52
10.6.3 Lubricating Seals and Threads 53
10.7 Installation 54
10.7.1 Control valve 54
10.8 Checking the function 56
10.8.1 Setting the valve stroke 56
NC: Valve in closed position 57
NO: Valve in open position 58
10.8.2 Valve Stroke 59
11 Alarms 60
11.1 Malfunctions and remedies 60
12 Decommissioning 61
12.1 Safety instructions 61
12.2 Disposal 61
12.2.1 General notes 61
12.2.2 Valve Actuator Disposal 61
13 Spare parts list - VARIVENT control valve type S S_F/S_J 62
14 Spare parts list - VARIVENT control valve type S, divert valve W/X 87
15 Spare parts list - VARIVENT control valve type S 3-stage seat K 92
16 Spare parts list – sterile lock HSP 97
17 Appendix 100
17.1 Lists 100
17.1.1 Abbreviations and terms 100
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1 General Information
1.1 Information on the Document
The present Operating Instructions are part of the user information for the
product. The Operating Instructions contain all the information you need to
transport, install, commission, operate and carry out maintenance for the product.
1.1.1 Binding Character of These Operating Instructions
These Operating Instructions contain the manufacturer's instructions to the
operator of the product and to all persons who work on or use the product
regarding the procedures to follow.
Carefully read these Operating Instructions before starting any work on or using
the product. Your personal safety and the safety of the product can only be
ensured if you act as described in the Operating Instructions.
Store the Operating Instructions in such a way that they are accessible to the
operator and the operating staff during the entire life cycle of the product. When
the location is changed or the product is sold make sure you also provide the
Operating Instructions.
1.1.2 Notes on the Illustrations
The illustrations in these Operating Instructions show the product in a simplified
form. The actual design of the product can differ from the illustration. For detailed
views and dimensions of the product please refer to the design documents.
1.1.3 Symbols and Highlighting
In these Operating Instructions, important information is highlighted by symbols
or special formatting. The following examples illustrate the most important types
of highlighting.
Danger
Warning: Fatal Injuries
Failure to observe the warning can result in serious damage to health, or
even death.
► The arrow identifies a precautionary measure you have to take to avoid
the hazard.
Warning: Explosions
Failure to observe the warning can result in severe explosions.
► The arrow identifies a precautionary measure you have to take to avoid
the hazard.
General Information
Information on the Document
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Warning!
Warning: Serious Injuries
Failure to observe the warning can result in serious damage to health.
► The arrow identifies a precautionary measure you have to take to avoid
the hazard.
Caution!
Warning: Injuries
Failure to observe the warning can result in minor or moderate damage to
health.
► The arrow identifies a precautionary measure you have to take to avoid
the hazard.
Notice
Warning: Damage to Property
Failure to observe the warning can result in serious damage to the
component or in the vicinity of the component.
► The arrow identifies a precautionary measure you have to take to avoid
the hazard.
Carry out the following steps: = Start of a set of instructions.
1. First step in a sequence of operations.
2. Second step in a sequence of operations.
®Result of the previous operation.
®The operation is complete, the goal has been achieved.
Hint!
Further useful information.
1.2 Manufacturer address
GEA Tuchenhagen GmbH
Am Industriepark 2-10
21514 Büchen
1.3 Contact
Tel.:[phone]
Fax:[phone]
[email protected]
www.gea.com
General Information
Manufacturer address
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1.4 EC Declaration of Conformity
General Information
EC Declaration of Conformity
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General Information
EC Declaration of Conformity
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Fig.1
General Information
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2 Safety
2.1 Intended use
The control valve S is used to control flow rates and pressures in automated
process plants.
The medium should preferably flow in the opening direction of the valve disk to
avoid pipe hammers when the valve is opened or closed.
Hint!
The manufacturer will not accept any liability for damage resulting
from any use of the valve which is not in accordance with the
designated use of the valve. The risk of such misuse lies entirely with
the operator of the facility.
2.1.1 Requirements for operation
The prerequisite for reliable and safe operation of the component is proper
transportation and storage as well as professional installation and assembly.
Operating the unit within the limits of its designated use also involves adhering to
the operating, inspection and maintenance instructions.
2.1.2 Pressure equipment directive
The component is a piece of pressure equipment (without safety function) in the
sense of the pressure equipment directive 2014/68/EU. Classified according to
Annex II in category 1.
According to the scope of directive 2014/34/EC, article 1, paragraph 2, f, the
exception of the directive applies, due to conformity with the machine directive
2006/42/EU.
The nominal diameters smaller than DN 25 are subject to article 4, paragraph 3
of the Pressure Equipment Directive which specifies sound engineering practice.
Nominal diameters ≥ IPS 4“; DN 125 valid for the fluid group II.
In the event of any deviations, GEA Tuchenhagen GmbH will supply a specific
Declaration of Conformity.
2.1.3 ATEX directive
In areas with an explosive atmosphere, only valves suitable for use in such areas
may be used.
Refer to and observe the additional operating instructions “ATEX version valves”.
For details regarding the marking of valves for potentially hazardous areas also
refer to the additional operating instructions “ATEX version valves”.
If these valves are used in areas with a potentially explosive atmosphere, you
must absolutely comply with directive 2014/34/EC with respect to all ignition
hazards.
2.1.4 Improper operating conditions
Safety
Intended use
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