GEA D-tec D User manual

Aseptic Valves
GEA D-tec® double-chamber valve type D/DV
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 D-tec® and TEFASEP® designations are trademarks of GEA Aseptomag AG
registered in Switzerland.
The designation T.VIS® is a protected trademark 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 for Complete Machines in accordance with the EC Machinery Directive
2006/42/EC, Annex II 1. A 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 Staff 12
2.7 Safety equipment 14
2.7.1 Signs 14
2.8 Residual dangers 16
2.9 Danger zones 17
3 Description 19
3.1 Design of the valve 19
4 Transport and storage 21
4.1 Storage conditions 21
4.2 Transport 21
4.2.1 Scope of supply 22
5 Technical data 23
5.1 Type plate 23
5.2 Technical data 23
5.3 Resistance of the sealing materials 24
5.4 Pipe ends - General table of measurements 26
5.5 Tool 26
5.6 Lubricants 27
5.7 Weights 28
6 Assembly and installation 29
6.1 Safety instructions 29
6.2 Notes on installation 29
6.3 Control head 29
6.4 Valve with Detachable Pipe Connection Elements 29
6.5 Valve with welded ends 30
6.6 Pneumatic connections 31
6.6.1 Air requirement 31
6.6.2 Establishing Hose Connections 31
Hose connection diagram - double-chamber valve type D/DV with control top T.VIS 32
Hose connection diagram - double-chamber valve D/DV without control top 33
6.7 Electrical connections 34
6.7.1 Electrical connection with T.VIS control top 34
6.7.2 Adjusting the initiator 35
7 Start-up 37
7.1 Safety notes 37
7.2 Notes on commissioning 37
8 Operation and control 38
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8.1 Safety instructions 38
9 Cleaning 39
9.1 Cleaning 39
9.1.1 Cleaning Process Examples 39
9.1.2 Cleaning effect 39
9.2 Sterilisation 40
9.3 Passivation 40
10 Maintenance 41
10.1 Safety instructions 41
10.2 Inspections 42
10.2.1 Leakage outlet 42
10.2.2 Pneumatic connections 42
10.2.3 Electrical connections 42
10.2.4 Signs on the valve 43
10.3 Servicing intervals 43
10.4 Prior to disassembly 45
10.5 Disassembling the valve 45
10.5.1 Disassembling the main valve 45
Removing the control top 46
Disconnecting the valve from the housing 48
10.5.2 Disassembling the valve insert of the main valve 50
10.5.3 Disassembling the side valve 56
10.5.4 Disassembling the valve insert of the side valve 57
10.6 Assembling the valve 59
10.6.1 Assembling the valve insert of the main valve 59
10.6.2 Assembling the main valve 67
10.6.3 Assembling the valve insert of the side valve 70
10.6.4 Assembling the side valves 71
10.6.5 Torques for the Clamps and Clamp Connections 72
10.6.6 Checking the function 73
10.7 Maintenance 75
10.7.1 Cleaning valve / replacing worn parts 76
10.7.2 Note on seal replacement 77
10.7.3 Replacing the V-ring 77
10.7.4 Changing the stem diaphragm 78
10.7.5 Exchanging the O-ring (TEFASEP gold) 78
10.7.6 Lubricating seals and threads 81
11 Alarms 82
11.1 Malfunctions and remedies 82
12 Decommissioning 83
12.1 Safety instructions 83
12.2 Disposal 83
12.2.1 General notes 83
12.2.2 Valve Actuator Disposal 83
13 Parts list - D-tec double-chamber valve type D/DV 84
14 Parts list - D-tec valve insert D/DV-SV-NC/NO 90
15 Parts list - lift actuator _LB-DV 95
16 Dimension sheet - double-chamber valve type D/DV 98
17 Appendix 102
17.1 Lists 102
17.1.1 Abbreviations and terms 102
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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 for Complete Machines in accordance with the EC
Machinery Directive 2006/42/EC, Annex II 1. A
Manufacturer: GEA Tuchenhagen GmbH
Am Industriepark 2-10
21514 Buchen, Germany
We as the manufacturer hereby declare in sole responsibility that the
machine designated below, based on its design and type as well as in the
version brought to market by us, complies with the basic safety and
health requirements of the EC Machinery Directive.
This declaration will become invalid if any alterations are made to the
machine which have not been agreed with us.
Designation: Valve with actuator
Type: D-tec® stem diaphragm
Model: N/DV, W/DV, P/DV, D/DV
Relevant EC directives: 2006/42/EC EC Machinery Directive
Applicable harmonized
standards, in particular:
DIN EN ISO 12100 Safety of Machines -
General design principles
- Risk assessment and
risk reduction
Other applied standards
and technical
specifications:
--
Remarks: We also declare that the relevant technical documentation for
this machine has been prepared in accordance with Annex
VII, Part A, and agree to submit the documentation on request
by the market supervisory authorities.
Person authorised for compilation and
handover of technical documentation:
GEA Tuchenhagen GmbH
CE Documentation Officer
Am Industriepark 2-10
21514 Buchen, Germany
Büchen, 08/08/2018
Michael Wulle
Managing
Director
i.V. Matthias Südel
Senior Director
Product Development Flow Components
General Information
EC Declaration of Conformity for Complete Machines in accordance with the EC Machinery Directive 2006/42/EC, Annex
II 1. A
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2 Safety
2.1 Intended use
Aseptic double-chamber valves are mix-proof stroke valves for highly hygienic
and 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).
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: Rinsing / sterilisation after transfer
CIP cleaning with seat lift
If seat lifting is activated for a CIP cleaning (preferably in cycles) no process must
be running in the opposite line. Furthermore, the outlet valve of the sterile
chamber to drain the CIP medium must be open.
Safety
Intended use
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Fig.3: Seat cleaning valve disk Fig.4: Seat cleaning double disk
The medium should preferably flow in the opening direction of the valve disk to
avoid pipe hammers when the valve is opened or closed. 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 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 component is a piece of pressure equipment (without safety function) in the
sense of the pressure equipment directive: Directive 2014/68/EG. They are
classified according to Annex II, article 4, section 3. 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.
Safety
Intended use
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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
Hint!
Negative pressure and switching under negative pressure in the
pipeline can lead to damage to the membrane.
2.2 Operator’s Duty of Care
In your capacity as operator of the facility you bear a particular responsibility for
the proper and safe handling of the valve in your facility. Only use the valve when
it is in perfect condition to prevent danger to persons and property.
These Operating Instructions contain the information you and your staff need for
the safe and reliable operation during the entire service life of the valve. 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 allow qualified staff to work on the valve.
•The operator must authorize the staff to carry out the relevant tasks.
•Working areas and the entire environment of the valve must be neat and
clean.
•The staff must wear suitable work clothing and personal protective equipment.
As the operator of the facility make sure that work clothing and personal
protective equipment are used.
•Instruct the staff with regard to any properties of the product which might pose
a health risk and the preventative measures to be taken.
•Have a qualified first-aider on call during the operation, who can initiate the
necessary first-aid measures in case of an emergency.
•Clearly define processes, lines of authority and responsibilities associated
with the valve. Everybody must know what to do in case of an emergency.
Instruct the staff in this respect at regular intervals.
•The signs relating to the valve must always be complete and legible. Check,
clean and replace the signs as necessary at regular intervals.
Safety
Operator’s Duty of Care
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•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
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 valve is operationally reliable. It was built according to state-of-the-art
science and technology.
Nevertheless, the valve can pose dangers, especially if
•the valve is not used in accordance with its intended use,
•the valve is not used correctly,
•the valve is operated under impermissible operating 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.
Safety
Subsequent changes
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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.
•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 Staff
This section contains information about the qualifications that staff working on the
valve must have.
Operating and maintenance staff 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.
Safety
Supplementary Regulations
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Only allow specially trained staff to carry out any work on explosion-protected
equipment. 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:
•Vocational training as a specialist who can work on the valve independently.
•Sufficient instruction to work on the valve under the supervision and direction
of a qualified specialist.
Each member of staff must meet the following requirements to be allowed to work
on the valve:
•Personal qualification for the relevant task.
•Sufficient professional qualification for the relevant task.
•Instructed with regard to the function of the valve.
•Instructed with regard to the operating sequences of the valve.
•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.
For work to be carried out on the valve the following user groups are
distinguished:
Safety
Qualification of Staff
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User groups
Staff Qualifications
Operating staff Adequate instruction and sound knowledge in the following areas:
•Function of the valve
•Valve operating sequences
•What to do in case of an emergency
•Lines of authority and responsibilities with respect to the task
Maintenance staff Adequate instruction as well as sound knowledge of the design
and function of the valve.
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 Signs
Hazardous locations on the component are marked by warning labels, prohibition
signs and mandatory signs.
The signs and instructions on the component must always be legible. Any
illegible signs must be replaced immediately.
Safety
Safety equipment
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Signs on the valve
Sign Meaning
Fig.5
General hazard warning
Fig.6
Warning Crushing
Fig.7
Explosive atmosphere hazard warning
Safety
Safety equipment
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2.8 Residual dangers
Dangerous situations can be avoided by safety-conscious and proactive
behaviour of the personnel 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.
Risk 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.
Safety
Residual dangers
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2.9 Danger zones
Fig.8: Danger zone at the valve
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.
•Never reach into the lantern (9) or the valve housing (401) when the valve is
switching. Fingers can be crushed or cut off.
•Do not reach into the feedback signal (E) when the valve is switching. Limbs
can be crushed or cut off.
•On a spring-closing valve there is danger of injury when the clamp
connections (43, 44.46) are opened, as the released spring pretension will
suddenly lift the actuator. Therefore, release the spring tension before
detaching the clamp connections (43, 44, 46) 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.
Safety
Danger zones
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•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.9: Design of the valve
Key
No. Designation
A Actuator
B T.VIS control top
C1 Inlet valve
C2 Outlet valve
L Lift actuator
P Air connection
1 Stem diaphragm
2 Stem diaphragm
5 O-ring
Description
Design of the valve
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Key
No. Designation
9 Lantern
10 Ring
12 Coupling
13 Stem
14 Bush
15 Valve disk
16 Double disk
24 Electrical connection
43 Clamp connection (safety device)
44 Clamp connection (safety device)
46 Clamp connection (safety device)
73 Leakage housing
401 Valve housing
Description
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