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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The operational safety of the component can not be guaranteed under improper
operating conditions. Therefore avoid improper operating conditions.
The operation of the component is not permitted if:
•Persons or objects are in the danger zone.
•Safety devices are not working or were removed.
•Malfunctions have been detected on the component.
•Damage to the component has been detected.
•Maintenance intervals have been exceeded.
2.2 Operator’s Duty of Care
The operating company of the component has a special responsibility for the
proper and safe handling of the component within their company. Only use the
component when it is in perfect operating condition in order to prevent danger to
persons and property.
This operating manual contains information that you and your employees need
for safe operation over the life of the component. Be sure to read these Operating
Instructions carefully and ensure that the measures described here are observed.
The operator's duty of care includes planning the necessary safety measures and
monitoring that these measures are observed. The following principles apply:
•Only qualified personnel may work on the component.
•The operating company must authorize personnel to carry out the relevant
tasks.
•Order and cleanliness must be maintained at the work stations and in the
entire area surrounding the component.
•Personnel must wear suitable work clothing and personal protective
equipment. As the operating company must ensure that work clothing and
personal protective equipment are used.
•Inform personnel regarding any properties of the product which might pose a
health risk and the preventative measures to be taken.
•Have a qualified first-aid representative on call during the operation. This
person must be able to initiate any necessary first-aid measures in case of an
emergency.
•Clearly define procedures, competences and responsibilities for those
working in the area of the component. Everybody must know what to do in
case of an emergency. Instruct the staff in this respect at regular intervals.
•The signs on the component must always be complete and easy to read.
Check, clean and replace the signs as necessary at regular intervals.
•Observe the Technical Data specified and the limits of use!
Safety
Operator’s Duty of Care
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Hint!
Carry out regular checks. This way you can ensure that these
measures are actually observed.
2.3 Subsequent changes
No technical modifications should ever be made to this component. Otherwise
you will have to undergo a new conformity process in accordance with the EC
Machinery Directive on your own.
In general, only original spare parts supplied by GEA Tuchenhagen GmbH
should be fitted. This ensures that the component is always operating properly
and efficiently.
2.4 General safety instructions and dangers
The component is safe to operate. It was built according to state-of-the-art
science and technology.
Nevertheless, dangers can arise from the component, if:
•the component is not used as intended
•the component is used improperly
•the component is operated under impermissible conditions
2.4.1 Principles for safe operation
Dangerous situations during operation can be avoided by safety-conscious and
proactive behaviour of the staff.
To ensure safe operation of the valve the following principles apply:
•The Operating Instructions must be kept ready to hand at the valve's place of
use. They must be complete and in clearly legible form.
•Only use the valve for its intended use.
•The valve must be functional and in good working order. Check the condition
of the valve before starting work and at regular intervals.
•Wear tight-fitting work clothing for all work on the valve.
•Ensure that nobody can get hurt on the parts of the valve.
•Immediately report any faults or noticeable changes on the valve to the
person responsible.
•Never touch the pipes and the valve when these components are hot! Avoid
opening the valve unless the process plants have been emptied and
depressurised.
•Observe the accident prevention regulations and all local regulations.
2.4.2 Environmental Protection
Harm to the environment can be avoided by safety-conscious and proactive
behaviour of the staff.
Safety
Subsequent changes
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For environmental protection the following principles apply:
•Substances harmful to the environment must not be discharged into the
ground or the sewage system.
•Always observe the pertinent regulations relating to waste avoidance,
disposal and utilization.
•Substances harmful to the environment must be collected and stored in
suitable containers. Clearly mark the containers.
•Dispose of lubricants as hazardous waste.
2.4.3 Electrical Equipment
For all work on electrical equipment, the following principles apply:
•Access to electrical equipment should only be allowed to qualified
electricians. Always keep unattended switch cabinets locked.
•Modifications of the control system can affect the safe and reliable operation.
Modifications are only permitted with the express permission of the
manufacturer.
•After completion of all work, check that the protective devices are fully
functional.
2.5 Supplementary Regulations
In addition to the instructions in this documentation the following also has to be
observed:
•pertinent accident prevention regulations,
•generally accepted safety rules,
•national regulations applicable in the country of use,
•work and safety instructions applicable in the facility,
•installation and operating regulations for use in potentially explosive areas.
2.6 Qualification of personnel
This section provides information on how the personnel working on the
component must be trained.
Operating and maintenance personnel must
•have the necessary qualification to carry out their tasks,
•be instructed with regard to possible dangers,
•know and observe the safety instructions given in the documentation.
Only allow qualified electricians to carry out work on the electrical equipment or
have a qualified electrician supervise the work.
Only allow specially trained personnel to carry out work on an explosion-
protected system. When working on explosion-protected equipment observe the
standards DIN EN 60079-14 for gases and DIN EN 50281-1-2 for dusts.
Safety
Supplementary Regulations
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The following minimum qualifications are required:
•Training as a specialist for working independently on the component.
•Adequate instruction to work on the component under the supervision and
guidance of a trained specialist
Each employee must meet the following requirements to work on the component:
•Personal suitability for the respective task.
•Sufficient professional qualification for the respective task.
•Received instruction about the functionality of the component.
•Received instruction about operating sequences on the component.
•Familiar with the safety devices and their function.
•Familiar with these Operating Instructions, especially with the safety
instructions and the information which is relevant for the task on hand.
•Familiar with the basic regulations with regard to occupational health and
safety and accident prevention.
When working with the component, a distinction is made between the following
user groups:
User groups
Staff Qualifications
Operating personnel Adequate instruction and sound knowledge in the following areas:
•Functionality of the component
•Operating sequences on the pump
•What to do in case of an emergency
•Lines of authority and responsibilities with respect to the task
Maintenance personnel Appropriate training and a sound knowledge of the structure and
functionality of the component.
Sound knowledge in the following areas:
•Mechanical equipment
•Electrical equipment
•Pneumatic system
Authorization with regard to safety engineering standards to carry
out the following tasks:
•Setting devices into operation
•Earthing of devices
•Marking of devices
The relevant certificates of qualification must be submitted before
work can be carried out on ATEX certified machines.
Safety
Qualification of personnel
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2.7 Safety equipment
2.7.1 Signage
Dangerous points on the valve are indicated by warning signs, prohibition signs
and mandatory signs.
The signs and notes on the valve must always be legible. Any illegible signs must
be replaced immediately.
Signs on the valve
Sign Meaning
Fig.2
General hazard warning
Fig.3
Warning Crushing
Fig.4
Explosive atmosphere hazard warning
2.8 Residual dangers
Dangerous situations can be avoided by safety-conscious and proactive
behaviour of the staff and by wearing personal protective equipment.
Residual dangers on the valve and measures
Danger Cause Measure
Danger to life Inadvertent switch-on of the
valve
Effectively disconnect all components, effectively prevent switch-
on.
Electric power Observe the following safety rules:
1. Isolate from the power supply.
2. Take appropriate measures to prevent switch on.
3. Test absence of voltage.
4. Earthing and short-circuiting.
5. Cover or safeguard any adjacent live parts.
Spring tension in the actuator Danger to life caused by compression spring in the actuator. Do
not open the actuator but return it to GEA Tuchenhagen for
proper disposal.
Safety
Safety equipment
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Residual dangers on the valve and measures
Danger Cause Measure
Danger of injury Danger presented by moving or
sharp-edged parts
The operator must exercise caution and prudence.
For all work:
•Wear suitable work clothing.
•Never operate the machine if the cover panels are not
correctly fitted.
•Never open the cover panels during the operation.
•Never reach into openings.
As a precautionary measure, wear personal protective equipment
in the vicinity of the valve:
•Protective gloves
•Safety shoes
Environmental damage Operating materials with
properties which are harmful to
the environment
For all work:
•Collect lubricants in suitable containers.
•Dispose of lubricants in accordance with the pertinent
regulations.
2.9 Danger zones
Please observe the following notes:
•In the event of malfunctions, shut down the valve (disconnect from the power
and air supply) and secure it against being used.
•When the valve is switching, never reach into the valve housing (391), the
motor stool (9) or into the valve inlet X (on pneumatic actuators). Fingers can
be crushed or cut off.
•When releasing the grooved cap nut (252) of the non-actuated valve (spring-
to-close version) there is a risk of the bellows and the round thread of the
grooved cap nut being damaged. Before releasing the grooved cap nut (252)
therefore relieve the spring tension by pressurizing the actuator with
compressed air. The valve is opened.
•The housing sockets have very sharp edges. When transporting and
assembling the valve therefore be sure to wear suitable protective gloves.
•Before starting any service, maintenance or repair work, disconnect the valve
from the power supply and secure it against inadvertently being switched
back on again.
•Only allow a qualified electrician to carry out any work on the electrical power
supply.
•Check the electrical equipment of the valve at regular intervals. Immediately
remedy loose connections and molten cables.
•If work on live parts cannot be avoided, call in a second person, who can
operate the main switch in case of an emergency.
Safety
Danger zones
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3 Description
3.1 Design
Fig.5
Description
Design
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Design
No. Designation
A Actuator
X Air connection
6 Coupling clips
9 Motor stool
10 Adapter
15 Valve disk
401 Valve housing
Description
Design
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3.2 Functional description
3.2.1 Spring-to-close actuator (Z)
The valve is closed in the non-actuated position.
In the standard version, the control valve is supplied with a spring-to-close
actuator – spring closed in the non-actuated position –, i.e.: If the input signal at
the positioner increases, the control valve opens.
3.2.2 Spring-to-open actuator (A)
The valve is open in the non-actuated position.
If the input signal at the positioner increases, the control valve closes.
Description
Functional description
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4 Transport and storage
4.1 Storage conditions
The valves, valve inserts or spare parts should be stored in a dry place, free of
vibrations and dust, and protected from light. To avoid damage, leave the
components in their original packaging if possible.
If, during transport or storage, the valve is going to be exposed to temperatures ≤
0°C, it must be dried beforehand and suitable measures must be taken to protect
it from damage.
Hint!
We recommend that the valve should be stored at a temperature of ≥ 5
°C for a period of 24 hours prior to any handling (disassembling the
housings / activation of actuators) so that any ice crystals formed by
condensation water can melt.
4.2 Transport
For transport, the following principles apply:
•Only use approved, fully functional means of transport, lifting gear and slings
that are suitable for the purpose to transport the package units/valves.
Observe the maximum load-bearing capacities.
•Observe the pictograms on the package.
•Handle valves with care to avoid damage caused by impact or careless
loading and unloading. The outside synthetic materials are susceptible to
breaking.
•Only allow qualified staff to transport the valve.
•Movable parts must be properly secured.
•Secure the valve against slipping. Take the weight of the valve into account
and the position of the point of gravity.
•Under no circumstances should anyone stand under a suspended load.
•Take care when transporting the valve. Do not grip sensitive parts of the unit
to lift or push the unit or to support yourself. Avoid putting the unit down with a
jerk.
4.2.1 Scope of supply
After taking delivery of the component, check if
•the details on the type plate correspond to the data in the order and delivery
documents,
•the equipment is complete and all components are in good order.
Transport and storage
Storage conditions
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