GEA Aseptomag AV User manual

Aseptic Valves
GEA Aseptomag® stop valve type AV
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 8
2.1.2 Pressure equipment directive 8
2.1.3 ATEX directive 8
2.1.4 Improper operating conditions 8
2.2 Operator’s Duty of Care 9
2.3 Subsequent changes 9
2.4 General safety instructions and dangers 10
2.4.1 Principles for safe operation 10
2.4.2 Environmental Protection 10
2.4.3 Electrical Equipment 11
2.5 Supplementary Regulations 11
2.6 Qualification of personnel 11
2.7 Safety equipment 12
2.7.1 Signage 12
2.8 Residual dangers 12
2.9 Danger zones 13
3 Description 15
3.1 Design of the valve 15
3.2 Valve Identification 16
3.3 Sealing Concepts 18
3.3.1 “Shrink-on Fit" Version 18
3.3.2 System "divisible" 18
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 Technical data 21
6 Assembly and installation 23
6.1 Safety instructions 23
6.2 Notes on installation 23
6.3 Welding In a Valve with Pipe Connection 23
6.3.1 Welding In and Installing a Valve 23
6.3.2 Welding post-treatment 24
6.4 Pneumatic connections 25
6.4.1 Air requirement 25
6.4.2 Establishing the Compressed Air Supply 26
6.5 Electrical connections 26
7 Start-up 27
7.1 Safety instructions 27
7.2 Notes on commissioning 27
8 Operation and control 28
8.1 Safety instructions 28
9 Cleaning 29
9.1 Cleaning 29
9.2 Sterilisation 29
9.3 Passivation 29
10 Maintenance 31
10.1 Safety instructions 31
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10.2 Inspections 32
10.2.1 Bellows 32
10.2.2 Pneumatic connections 32
10.2.3 Electrical connections 32
10.3 Maintenance intervals 32
10.4 List of tools 33
10.5 Prior to disassembly 37
10.6 Disassembling and Assembling the Valve 38
10.6.1 Disassembling the valve 38
10.6.2 Assembling the valve 40
10.6.3 Torques for clamp 40
10.7 Disassembling and Assembling the Internal Assembly 40
10.7.1 Disassembling the internal assembly 40
10.7.2 Assembling the internal assembly 42
10.8 Removing and Installing the "Shrunk-on” Valve Seat Seal 42
10.8.1 Removing the “Shrink-on Fit” Valve Seat Seal 42
10.8.2 Fitting the “Shrink-on Fit” Valve Seat Seal 43
10.9 Removing and Installing the "Divisible System" Valve Seat Seal 45
10.9.1 Removing the Divisible Valve Seat Seal 45
10.9.2 Fitting the Divisible Valve Seat Seal 47
10.9.3 Torques for Divisible Valve discs 47
10.10 Carrying out the "Internal assembly" leak test (bubble test) 48
10.11 Disassembling and Assembling Actuator PA50/PA60 50
10.11.1 Disassembling Actuator PA50/PA60 50
10.11.2 Assembling Actuator PA50/PA60 55
10.12 Disassembling and Assembling Actuator PA80 - PA255 55
10.12.1 Disassembling Actuator PA80 - PA255 55
10.12.2 Assembling Actuator PA80 - PA255 58
10.13 Disassembling and Assembling Actuator PA80AZ - PA180AZ 60
10.13.1 Disassembling Actuator PA80AZ - PA180AZ 60
10.13.2 Assembling Actuator PA80AZ - PA180AZ 63
10.14 Maintenance 63
10.15 Checking the Feedback Unit 65
10.15.1 Setting the Feedback Unit 65
10.15.2 Valve Stroke 65
11 Alarms 66
11.1 Malfunctions and remedies 66
12 Decommissioning 68
12.1 Safety instructions 68
12.2 Disposal 68
12.2.1 General notes 68
13 Appendix 69
13.1 Lists 69
13.1.1 Abbreviations and terms 69
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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 stop valves of type AV are stroke valves and are used for opening and
closing pipes in aseptic process plants in a controlled manner. Welded metal
bellows (or PTFE bellows as an option) are used to hermetically seal the valve
disc. Selected sealing materials in the product chamber ensure optimum
tightness. The valve offers a high degree of process reliability and product quality
in aseptic working processes.
Pressure hammers and excessive control air pressures can destroy the bellows.
The control air pressure should therefore not exceed 8 bar and pressure
hammers in the system should be avoided.
The stop valve AV should close against the direction of flow of the medium if
possible. Should this not be possible due to technical reasons related to the plant
or process, the valve must be depressurized. Both measures prevent pressure
hammers when the valve is opened or closed. The valve is monitored, controlled
and operated by the customer's installation.
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 is borne solely by the operating
company.
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
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 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:
Safety
Intended use
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•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!
Hint!
Carry out regular checks. This way you can ensure that these
measures are actually observed.
2.3 Subsequent changes
Safety
Operator’s Duty of Care
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You should never make any technical modifications to the valve. 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 Aseptomag AG should be
fitted. This ensures the reliable and economical operation of the valve.
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.
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.
Safety
General safety instructions and dangers
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•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.
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.
Safety
Supplementary Regulations
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•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.
2.7 Safety equipment
2.7.1 Signage
No warning signs are affixed to this valve.
2.8 Residual dangers
Dangerous situations can be avoided by safety-conscious and proactive
behaviour of the personnel and by wearing personal protective equipment.
Safety
Safety equipment
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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.
Risk of injury •Danger
presented by
moving or
sharp-edged
parts
•Danger due to
escaping
media with
properties that
are dangerous
to health
Effectively prevent unauthorised persons from
manipulating the valve. 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 and cleaning solutions in suitable
containers.
•Dispose of lubricants and cleaning solutions in
accordance with the pertinent regulations.
2.9 Danger zones
Please observe the following notes:
Safety
Danger zones
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Fig.1: Danger zone at the valve
•In the event of malfunctions, shut down the valve (disconnect from the power
and air supply) and secure it against being used.
•Never reach into the lantern (1) or the valve housing (2) when the valve is
switching. There is a danger of injury to fingers.
•With a closed valve there is danger of injury when the clamp (3) is opened
since the released closing pressure will suddenly lift the actuator. Therefore,
release the closing pressure by opening the valve before detaching the clamp
(3) by supplying the actuator (A) with compressed air.
•Before starting any maintenance, servicing 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.
•The housing sockets have very sharp edges. When transporting and
assembling the valve be sure to wear suitable protective gloves.
Safety
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3 Description
3.1 Design of the valve
Fig.2: Main components on the valve
Key
No. Designation
1 Housing
2 Internal assembly
3 Actuator
4 Clamp (safety device)
Description
Design of the valve
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3.2 Valve Identification
Reference numbers from the following number systems are assigned to each part
of components from GEA Aseptomag AG. The reference numbers can be used to
clearly identify a component and its composition.
Number
(Example) Designation Description
0001 14 Serial valve
number
The valve serial number is the easiest and most definite
way to identify a component from GEA Aseptomag AG.
This number is unique and allows all components
installed at the time of delivery to be identified. The first
four digits represent a chronological, ascending number,
the last two digits provide information about the year of
manufacture. The valve's serial number is indicated on a
round white sticker affixed to the actuator.
0001 14 Serial number
main components
The serial number has the same structure as the valve's
serial number, but it is placed on the relevant main
component (housing, internal assembly, actuator) by
laser marking / stamping.
V-50-1001 Drawing number The drawing number is a combination of two groups. The
digits in front of the hyphen refer to where the
components belong to. The next four numbers describe
the part in more detail. For this purpose, the main
component groups of a valve are assigned to various
groups:
•V-xx-0xxx = entire valves
•V-xx-1xxx = valve housings
•V-xx-2xxx = internal assemblies
•V-xx-3xxx = actuators
•V-xx-4xxx = feedback units / accessories
Each of these main components is marked and can be uniquely identified.
! Other markings on components of the valve, such as on sockets, arise from the
production process and are not relevant.
Description
Valve Identification
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1 2 3 456
Fig.3: Designations on the valve
Key
No. Example Position Details
1 V-50-1002
1.4435 TC 333937
Valve
housing
Drawing number of valve housing
Material and re-stamping details
2 0548 10 Valve
housing
Serial number of valve housing
3 V-50-1004 Clamp Number of clamp drawing
4 V-50-2200
1424 10
Internal
assembly
Drawing number of internal assembly
Serial number of internal assembly
5 1216 10 Actuator Sticker with valve serial number
6 PA100/50 NC
V-50-3000
0977 10
Actuator Designation of actuator
Number of actuator drawing
Serial number of actuator
Description
Valve Identification
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3.3 Sealing Concepts
3.3.1 “Shrink-on Fit" Version
•Undivided valve disk
•GEA Aseptomag standard
•For hard sealing materials such as TEFASEP®, PTFE or reinforced PTFE
Fig.4: "Shrink-on Fit" Version
3.3.2 System "divisible"
Valve seat seals
TVT Divisible valve disk, valve seat seal TEFASEP®
TVE Divisible valve disk, valve seat seal EPDM (form seal)
TVPVF Divisible valve disk, valve seat seal reinforced PTFE (form
seal)
Concept for O-rings
•Divisible valve disk
•GEA Aseptomag option
•For sealing materials such as TEFASEP® (TVT)
•Additional O-ring behind the valve seat seal
Fig.5: System “divisible” for O-rings
Concept for form seals
•Divisible valve disk
•GEA Aseptomag option
•For sealing materials such as EPDM (TVE) or reinforced PTFE (TVPVF)
•Form-seal with moulded-on retention flag
Description
Sealing Concepts
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Fig.6: System “divisible” for O-rings
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 suitable lifting gear and slings for transporting the package units/
valves.
•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.
•Control tops (if fitted) must be protected from animal and vegetable fats.
•Only allow qualified staff to transport the valve.
•Movable parts must be properly secured.
•Only use approved, fully functional load lifting devices and lifting accessories
which are suitable for the intended purpose. Observe the maximum load-
bearing capacities.
•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
On receipt of the valve check whether
•the details on the main valve components 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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