GEA ECOspace User manual

Hygienic valves
GEA hygienic leakage butterfly valve type ECOspace
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 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 EU Declaration of Conformity in accordance with the EC Machinery Directive 2006/42/EC 7
1.5 Translated copy of the EU - Declaration of conformity in accordance with the Pressure Equipment Directive
2006/42/EU 8
2 Safety 9
2.1 Intended use 9
2.1.1 Flow speed 9
2.1.2 Pressure equipment directive 9
2.1.3 ATEX directive 9
2.1.4 Improper operating conditions 9
2.1.5 Requirements for operation 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 11
2.4.3 Electrical Equipment 12
2.5 Supplementary Regulations 12
2.6 Qualification of personnel 12
2.7 Safety equipment 13
2.7.1 Signage 13
2.8 Residual dangers 14
2.9 Hazard Areas 15
3 Description 17
3.1 Pneumatic Butterfly Valve with Control Top 17
3.2 Pneumatic Butterfly Valve without Control Top 17
3.3 Butterfly Valve Body without Actuator 18
3.4 Manual Actuator Type H 18
3.5 Functional description 19
3.5.1 Pneumatic Actuator 19
3.5.2 Actuator (A.1) 19
3.5.3 Actuator (A.2) 19
3.5.4 Manual Actuator Type H 20
3.5.5 Butterfly Valve Body without Actuator 20
4 Transport and storage 22
4.1 Storage conditions 22
4.2 Transport 22
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 Sealing Materials 25
5.4 Pipe ends - General table of measurements 26
5.5 Tools 27
5.6 Lubricants 28
5.7 Weights 28
6 Assembly and installation 29
6.1 Safety instructions 29
6.2 Notes on installation 29
6.3 Pneumatic connections 29
6.3.1 Air Requirement 29
6.3.2 Establishing Hose Connections 30
6.3.3 Actuator with T.VIS Control Top 30
6.3.4 Actuator without Control Top 30
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6.4 Electrical connections 30
6.4.1 Electrical connection with T.VIS control top 31
6.4.2 Adjusting the proximity switch – actuator without T.VIS 31
7 Start-up 33
7.1 Safety instructions 33
7.2 Notes on commissioning 33
8 Operation and control 34
8.1 Safety instructions 34
9 Cleaning 35
9.1 Cleaning 35
9.1.1 Cleaning Process Examples 35
9.1.2 Cleaning effect 35
9.1.3 Cleaning the Leakage Cavity 36
9.2 Passivation 37
10 Maintenance 38
10.1 Safety notes 38
10.2 Inspections 39
10.2.1 Pneumatic connections 39
10.2.2 Electrical connections 39
10.2.3 Mechanical Connections 39
10.2.4 Signs on the valve 39
10.3 Maintenance intervals 40
10.4 Prior to disassembly 40
10.5 Disassembling the Valve 40
10.5.1 Removing the T.VIS M-15 Control Top 41
10.5.2 Removing the T.VIS A-15 Control Top 42
10.5.3 Removing the Valve 43
10.5.4 Disassembling the Pneumatic Actuator 43
Taking off the Actuator 43
Dismantling the Actuator Parts 44
10.5.5 Disassembling the Manual Actuator 44
10.5.6 Removing the Valve Disk Seal 45
10.6 Maintenance 46
10.6.1 Cleaning the Mixproof Butterfly Valve 46
10.6.2 Lubricating Seals and Threads 47
10.7 Installation 48
10.7.1 Assembling the Valve Disk 48
10.7.2 Torques for the clamps and bolts 49
11 Alarms 50
11.1 Malfunctions and remedies 50
12 Decommissioning 51
12.1 Safety instructions 51
12.2 Disposal 51
12.2.1 General notes 51
12.2.2 Valve Actuator Disposal 51
13 Parts list - Hygienic leakage butterfly valve ECOspace 52
14 Spare parts list - Pneumatic actuator hygienic leakage butterfly valve 54
15 Dimension sheet - Manual operation hygienic leakage butterfly valve 57
16 Dimension sheet - Hygienic leakage butterfly valve ECOspace 59
17 Dimension sheet - Hygienic butterfly valve - seals 61
18 Appendix 63
18.1 Lists 63
18.1.1 Abbreviations and terms 63
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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 EU Declaration of Conformity in accordance with the EC Machinery Directive
2006/42/EC
1/1
GEA INTERNAL
EU Declaration of conformity within the meaning of the EC machine directive 2006/42/EC
Manufacturer:
GEA Tuchenhagen GmbH
Am Industriepark 2-10
21514 Büchen, Germany
Hereby, we declare that the machine designated in the following
Designation: GEA Hygienic Butterfly Valve
GEA Hygienic Leakage Butterfly Valve
Type: Valve with actuator
by virtue of its design and construction and in the versions placed on the market by us, complies with the essential health
and safety requirements of the following directive:
Relevant EC directives:
2006/42/EC
EC Machinery Directive
Applicable harmonized standards, in particular:
EN ISO 12100: 2010
Remarks:
•In the event of a modification to the machine that was not agreed with us, this declaration loses its
validity
•Furthermore, we declare that the specific technical documentation for this machine has been drawn
up in accordance with Annex VII, Part A, and undertake to forward this documentation by means of
data medium upon justified request by the national authorities
Person authorised for compilation and handover of technical
documentation:
GEA Tuchenhagen GmbH
CE Documentation Officer
Am Industriepark 2-10
21514 Büchen, Germany
Büchen, 29 April 2021
________________________________ ________________________________
Franz Bürmann pp. Matthias Südel
Managing Director Head of Engineering
General Information
EU Declaration of Conformity in accordance with the EC Machinery Directive 2006/42/EC
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1.5 Translated copy of the EU - Declaration of conformity in accordance with the
Pressure Equipment Directive 2006/42/EU
Manufacturer:
GEA Tuchenhagen GmbH
Am Industriepark 2-10
21514 Büchen
We hereby declare that the machine named below
Designation: GEA Hygienic butterfly valve
GEA Hygienic leakage butterfly valve
Type: Valve with actuator
due to its design and construction as well as in the versions sold by us,
meet the basic safety and health requirements of the following guideline:
Relevant EC directives: 2006/42/EC EC Machinery Directive
Applicable harmonized
standards, in particular:
DIN EN ISO 12100
Remarks: This declaration will become invalid if
any alterations are made to the
machine which have not been agreed
with us.
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
justified request of national authorities
on a data carrier.
Person authorised for compilation and
handover of technical documentation:
GEA Tuchenhagen GmbH
CE Documentation Officer
Am Industriepark 2-10
21514 Büchen
Büchen, 29 April 2021
Franz Bürmann
Managing Director i.V. Matthias Südel Head of Engineering
General Information
Translated copy of the EU - Declaration of conformity in accordance with the Pressure Equipment Directive 2006/42/EU
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2 Safety
2.1 Intended use
The Mixproof Butterfly Valve is used for the separation of media in pipe sections.
Using the device for any other purpose is considered contrary to its designated
use.
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 Flow speed
With slow flow speeds, existing solids holding space can potentially settle.
When the butterfly valve is closed quickly, this causes negative pressure on the
disk and in the area of the butterfly valve seal, as a result of a stall. With flow
speeds of ≥ 3.5 m/s, the valve may only be closed with significantly reduced
speed.
2.1.2 Pressure equipment directive
The Mixproof Butterfly Valves are 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.
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:
•Persons or objects are in the danger zone.
•Safety devices are not working or were removed.
•Malfunctions have been detected on the component.
Safety
Intended use
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•Damage to the component has been detected.
•Maintenance intervals have been exceeded.
2.1.5 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.
2.2 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.
Safety
Operator’s Duty of Care
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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.
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.
Safety
Subsequent changes
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•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.
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:
Safety
Supplementary Regulations
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•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.
2.7 Safety equipment
2.7.1 Signage
Dangerous points on the valve are indicated by warning signs, prohibition signs
and mandatory signs.
Safety
Safety equipment
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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.1
General hazard warning
Fig.2
Warning Crushing
Fig.3
Explosive atmosphere hazard warning
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.
Safety
Residual dangers
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Residual dangers on the valve and measures
Danger Cause Measure
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.
Risk of injury Danger due to liquid escaping
from the leakage connections Discharge the liquid in a controlled manner.
2.9 Hazard Areas
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 pipe Y or into bracket X (on
pneumatic actuators). Fingers can be crushed or cut off.
Safety
Hazard Areas
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•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
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3 Description
3.1 Pneumatic Butterfly Valve with Control Top
Fig.4
No. Designation
A.1 Pneumatic Actuator
B T.VIS control top
1 Mounting bracket
2 Butterfly valve body
3.2 Pneumatic Butterfly Valve without Control Top
Fig.5
No. Designation
A.2 Pneumatic Actuator
1 Mounting bracket
2 Butterfly valve body
Optional Electrical feedback - proximity switch
in the mounting bracket
Description
Pneumatic Butterfly Valve with Control Top
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3.3 Butterfly Valve Body without Actuator
Fig.6
Butterfly valve design for matrix-piped systems.
3.4 Manual Actuator Type H
Various manual actuator variants are available.
Standard design of manual actuator
Fig.7
No. Manual actuator variants
1 Standard
2 Optional – one electrical feedback signal
3 Optional – two electrical feedback signals
Description
Butterfly Valve Body without Actuator
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3.5 Functional description
3.5.1 Pneumatic Actuator
The compressed air which enters above the piston causes a downwards
movement of the piston and the disk of the butterfly valve opens. When the air
supply is shut off, the valve closes automatically as a result of the spring force.
The stroke of the piston is converted into a rotary movement of the shaft. The
travel of the piston is limited, so that the shaft performs a 90° rotation per stroke.
This rotation exactly corresponds to the rotational angle required to open or close
the disk of the mixproof butterfly valve.
3.5.2 Actuator (A.1)
Fig.8
The switching state is detected and indicated by the control top (B).
The visual position indication (O) can be recognized by the red marking on the
coupling.
3.5.3 Actuator (A.2)
Fig.9
Feedback of switching states can be provided by proximity switches in the
mounting bracket (1).
The visual position indication (O) can be recognized by the red marking on the
coupling.
Description
Functional description
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3.5.4 Manual Actuator Type H
Fig.10
To open or close the mixproof butterfly valve, unlock the hand lever (1) by gently
pulling it out of the locking device and turn it through 90°. When the lever is
released, it locks into place in the holes provided. The limit positions of the
mixproof butterfly valve can be detected by proximity switches.
3.5.5 Butterfly Valve Body without Actuator
Fig.11
No. Designation
1 Valve disk
2 Flange
3 Flange
4 Disk seal
5 Plain bearing
6 Radial seal
7 Leakage connections
8 Hole on the square end
Description
Functional description
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