GEA Aseptomag ADV User manual

Aseptic Valves
GEA Aseptomag® leakage valve type ADV
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
Aseptomag® and TEFASEP® are registered trademarks of GEA Aseptomag AG
and may not be used without the permission of GEA Aseptomag AG.
T.VIS® is a protected trademark of GEA Tuchenhagen GmbH.
We kindly request that you answer a few short questions about these Operating
Instructions. Use the following QR code or link to access the questionnaire:
https://www.ntgt.de/ra/s.aspx?s=367112X57707125X58087
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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 Customer service 6
1.4 EC Declaration of Incorporation 7
2 Safety 8
2.1 Intended use 8
2.1.1 Requirements for operation 9
2.1.2 Pressure equipment directive 9
2.1.3 ATEX directive 9
2.1.4 Improper operating conditions 10
2.2 Operator’s Duty of Care 10
2.3 Subsequent changes 11
2.4 General safety instructions and dangers 11
2.4.1 Principles for safe operation 11
2.4.2 Environmental Protection 12
2.4.3 Electrical Equipment 12
2.5 Supplementary Regulations 12
2.6 Qualification of personnel 12
2.7 Safety equipment 14
2.7.1 Signage 14
2.8 Residual dangers 14
2.9 Danger zones 15
3 Description 17
3.1 Design of the Valve 17
3.2 Valve Identification 18
3.3 Sealing Concepts 20
3.3.1 System "separable" 20
4 Transport and storage 21
4.1 Storage conditions 21
4.2 Transport 21
4.2.1 Scope of supply 21
5 Technical data 22
5.1 Technical data 22
6 Assembly and installation 24
6.1 Safety instructions 24
6.2 Notes on installation 24
6.3 Welding In a Valve with Pipe Connection 24
6.3.1 Welding In and Installing a Valve 24
6.3.2 Welding post-treatment 25
6.4 Pneumatic connections 26
6.4.1 Overview switching positions 26
6.4.2 Air Requirement 26
6.4.3 Establishing the Compressed Air Supply 27
6.5 Electrical connections 27
7 Start-up 28
7.1 Safety instructions 28
7.2 Notes on commissioning 28
8 Operation and control 29
8.1 Safety instructions 29
9 Cleaning 30
9.1 Cleaning 30
9.2 Sterilisation 30
9.3 Passivation 30
10 Maintenance 32
10.1 Safety instructions 32
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10.2 Inspections 33
10.2.1 Bellows 33
10.2.2 Pneumatic connections 33
10.2.3 Electrical connections 33
10.3 Maintenance intervals 33
10.4 List of tools 34
10.5 Prior to disassembly 38
10.6 Disassembling and Assembling the Valve 38
10.6.1 Disassembling the Valve 38
10.6.2 Assembling the Valve 41
10.6.3 Torques for clamp 42
10.7 Disassemble and assemble actuator PA20 (side valve) 42
10.7.1 Disassemble actuator PA20 (side valve) 42
10.7.2 Assemble actuator PA20 (side valve) 43
10.8 Disassembling and Assembling the Internal Assembly 44
10.8.1 Disassembling the Internal Assembly 44
10.8.2 Assembling the Internal Assembly 45
10.9 Removing and Installing the "Divisible System" Valve Seat Seal 46
10.9.1 Removing the Divisible Valve Seat Seal 46
10.9.2 Fitting the Divisible Valve Seat Seal 47
10.9.3 Torques for divisible valve discs 50
10.10 Carrying out the “Internal Assembly” Leak Test (Bubble Test) 50
10.11 Disassembling and Assembling Actuator PA80 - PA255 52
10.11.1 Disassembling Actuator PA80 - PA255 52
10.11.2 Assembling Actuator PA80 - PA255 55
10.12 Disassembling and Assembling Actuator PA80AZ - PA180AZ 57
10.12.1 Disassembling Actuator PA80AZ - PA180AZ 57
10.12.2 Assembling Actuator PA80AZ - PA180AZ 60
10.13 Maintenance 60
10.14 Checking the Feedback Unit 62
10.14.1 Setting the Feedback Unit 62
10.14.2 Valve Stroke 62
11 Alarms 63
11.1 Malfunctions and remedies 63
12 Decommissioning 65
12.1 Safety instructions 65
12.2 Disposal 65
12.2.1 General notes 65
13 Appendix 66
13.1 Lists 66
13.1.1 Abbreviations and terms 66
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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 Aseptomag AG
Industrie Neuhof 28
CH-3422 Kirchberg
1.3 Customer service
Phone: [phone]
Fax: [phone]
[email protected]
www.gea.com
General Information
Manufacturer address
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1.4 EC Declaration of Incorporation
GEA Aseptomag AG
Tel. [phone] · Fax [phone] · gea.com
Industrie Neuhof 28, CH-3422 Kirchberg Seite 1 von 1
Kirchberg, 16.12.16
Declaration of
Incorporation
According 2006/42/EC from 09.06.2006, appendix II B
INCORPORATION OF PARTLY COMPLETED MACHINERY
We herewith declare that the subsequently described partly completed machine complies with the below listed
essential requirements of the machine directive 2006/42/EC. The technical documentation is compiled in
accordance with part B of Annex VII. In response to reasonable request the relevant technical documentation
will be provided to the national authorities in printed or electronic format (PDF).
Manufacturer: GEA Aseptomag AG
Industrie Neuhof 28
CH-3422 Kirchberg
Authorized person: GEA Aseptomag AG
Engineering Department
Industrie Neuhof 28
CH-3422 Kirchberg
Commercial name of the machine: Valve
Machine type: Aseptomag®Valve Technology
Serial number: xxxx yy (x = serially numbered, y = year of manufacture)
Respective EC standard: 2006/42/EC
Essential requirements: Appendix I, section 1 and 2.1
Applied harmonized standards: DIN EN ISO 12100:2010
The commissioning of this partly completed machine is prohibited until the final machinery into which it is to be
incorporated has been declared in conformity with the provisions of the Machine Directive 2006/42/EC.
Reimar Gutte i.A. Aron Stauffer
Management Board Teamleader Product Development
GEA Aseptomag AG Flow Components –Aseptic Valves
General Information
EC Declaration of Incorporation
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2 Safety
2.1 Intended use
Aseptic leakage valves are mix-proof switch elements for aseptic process
systems and permit the safe separation of incompatible media. The media
separation is done via the integrated sterile chamber (ISB), which is separated
hermetically from the atmosphere with a seal each to both product lines and via
two side valves (inlet and outlet). Any leakage at the sealing elements is diverted
through the side valves.
For safe operation, it is mandatory that the following points are observed in the
different process steps:
Transfer
During a media transfer through the main valve both side valves must be closed
completely.
Fig.1: Product transfer
Cleaning sterile chamber
After a media transfer the sterile chamber must be flushed at least with one
sterile medium. After the main valve has been closed, both side valves can be
put in the open position and thus permit the flushing of the sterile chamber.
Fig.2: Sterilisation after transfer
Safety
Intended use
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CIP cleaning with seat venting (valve type AZ)
If the seat venting is activated for a CIP cleaning (preferably in cycles) no process
must be running in the opposite line. Furthermore, at least one side valve of the
sterile chamber must be open to drain the CIP medium.
Fig.3: Cleaning valve seat B
Pressure hammers and excessive control air pressure (>8 bar) can damage the
bellow. Therefore, Aseptic Leakage Valves (ADV) should if possible, close
against the flow direction of the medium. Should this not be possible due to
technical reasons related to the plant or process, it is recommended to switch the
valve without pressure. Both measures prevent pressure hammers when the
valve is opened or closed.
The valve is monitored, controlled and operated by the customer's system.
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 valve is a piece of pressure equipment (without safety function) as defined in
the Pressure Equipment Directive: Directive 2014/68/EG. It is classified according
to Annex II, article 4, section 3. In the event of any deviations, GEA Aseptomag
AG will supply a specific Declaration of Conformity.
2.1.3 ATEX directive
Safety
Intended use
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Aseptomag ® valve technology can also be used in ATEX protected areas.
However, the suitability of the component must be checked under consideration
of the respective conditions. Additional information will be made available upon
request.
2.1.4 Improper operating conditions
The operational reliability of the valve cannot be ensured under improper
operating conditions. Therefore avoid improper operating conditions.
Operating the valve 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 valve.
•Damage has been detected on the valve.
•Maintenance intervals have been exceeded.
•the position of the side valves is not adjusted to the process steps
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.
Safety
Operator’s Duty of Care
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