GEA T-smart 7 User manual

Hygienic valves
GEA T-smart 7 butterfly valve
Operating instruction (Translation from the original language)
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COPYRIGHT
These Operating Instructions are the English translation of the original operating
instructions in the sense of the EU Machinery Directive. This document is
protected by copyright. All rights reserved. The document may not, in whole or in
part, be copied, reproduced, translated or reduced to an electronic medium of
machine-readable form without the express permission of GEA Tuchenhagen
GmbH.
LEGAL NOTICE
Word marks
The designations VARIVENT® and T.VIS® are protected trademarks of GEA
Tuchenhagen GmbH.
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 Contact 6
1.4 EU Declaration of Conformity for Machines 7
2 Safety 8
2.1 Intended use 8
2.1.1 Requirements for operation 8
2.1.2 Flow speed 8
2.1.3 Pressure equipment directive 8
2.1.4 ATEX directive 8
2.1.5 Improper operating conditions 8
2.2 Operator’s Duty of Care 9
2.3 Subsequent changes 10
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 13
2.9 Hazard Areas 14
3 Description 16
3.1 Butterfly valve with control top 16
3.2 Butterfly valve without control top 16
3.3 Intermediate flange design – VV (788) 17
3.4 Manual actuator 17
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 21
4.1 Storage conditions 21
4.2 Transport 21
4.2.1 Scope of supply 21
5 Technical data 22
5.1 Type plate 22
5.2 Technical data 22
5.3 Resistance of Sealing Materials 24
5.4 Pipe ends - General table of measurements 25
5.5 Tool 26
5.6 Lubricants 27
5.7 Weights 27
6 Assembly and installation 29
6.1 Safety instructions 29
6.2 Notes on installation 29
6.3 Butterfly Valve with Welding Flange Design 29
6.4 Butterfly Valve with Intermediate Flange Design 30
6.5 Butterfly valve with screw connection (G, K, C) 31
6.6 Pneumatic connections 31
6.6.1 Air Requirement 32
6.6.2 Establishing Hose Connections 32
6.6.3 Actuator with T.VIS Control Top 32
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6.6.4 Actuator without Control Top 32
6.7 Electrical connections 32
6.7.1 Electrical connection with T.VIS control top 33
6.7.2 Adjusting the proximity switch – actuator without T.VIS 33
7 Start-up 35
7.1 Safety instructions 35
7.2 Notes on commissioning 35
8 Operation and control 36
8.1 Safety instructions 36
9 Cleaning 37
9.1 Cleaning 37
9.1.1 Cleaning Process Examples 37
9.1.2 Cleaning effect 37
9.1.3 Rinsing operations 38
9.2 Passivation 38
10 Maintenance 39
10.1 Safety instructions 39
10.2 Inspections 40
10.2.1 Pneumatic connections 40
10.2.2 Electrical connections 40
10.2.3 Mechanical Connections 40
10.3 Maintenance intervals 41
10.4 Prior to disassembly 41
10.5 Disassembling the Valve 41
10.5.1 Removing the T.VIS M-15 Control Top 42
10.5.2 Removing control top type T.VIS P-15 and A-15 43
10.5.3 Removing the proximity switch – actuator without T.VIS 44
10.5.4 Intermediate flange design type VV – removing the valve 44
10.5.5 Disconnecting the actuator 44
10.5.6 Dismantling the Actuator Parts 45
10.5.7 Removing the manual actuator H 46
10.5.8 Removing the Valve Disk Seal 46
10.6 Maintenance 49
10.6.1 Cleaning the Valve 49
10.6.2 Lubricating Seals and Threads 50
10.7 Installation 51
10.7.1 Assembling the Valve Disk 51
10.7.2 Torques for the Clamps and Clamp Connections 52
11 Alarms 53
11.1 Malfunctions and remedies 53
12 Decommissioning 54
12.1 Safety instructions 54
12.2 Disposal 54
12.2.1 General notes 54
12.2.2 Valve Actuator Disposal 54
13 Parts list - Manual actuator for butterfly valve T-smart 7 55
14 Spare parts list - Pneumatic actuator 57
15 Parts list - Butterfly valve body T-smart 7 61
16 Parts list - Butterfly valve 788 77
17 Dimension sheet - T-smart 7 83
18 Dimension sheet - Butterfly valve T-smart 7 VV 88
19 Dimension sheet - Butterfly valve T-smart 7 - flanges 91
20 Appendix 94
20.1 Lists 94
20.1.1 Abbreviations and terms 94
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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 for Machines
in accordance with the EC Machinery Directive 2006/42/EC, Annex II 1. A
Manufacturer:
GEA Tuchenhagen GmbH
Am Industriepark 2-10
21514 Büchen
We declare under our sole responsibility that the machine
Designation: Valve with actuator
Type: T-smart
conforms with all the relevant provisions of this directive and the
following directives:
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
justified request of national authorities
on a data carrier.
Person authorised for compilation and
handover of technical documentation:
Person authorised to compile the
technical file for CE marking
GEA Tuchenhagen GmbH
Am Industriepark 2-10
21514 Büchen
Büchen, 16/02/2015
Franz Bürmann
Managing Director
i.V. Matthias Südel
Senior Director
Product Development
Flow Components
General Information
EU Declaration of Conformity for Machines
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2 Safety
2.1 Intended use
The butterfly valve is used to open and partially or fully shut off 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 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 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.
2.1.3 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. 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.
2.1.4 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.
2.1.5 Improper operating conditions
The operational safety of the component can not be guaranteed under improper
operating conditions. Therefore avoid improper operating conditions.
Safety
Intended use
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The operation of the component is not permitted if:
•Persons or objects are in the danger zone.
•Safety devices are not working or were removed.
•Malfunctions have been detected on the component.
•Damage to the component has been detected.
•Maintenance intervals have been exceeded.
2.2 Operator’s Duty of Care
The operating company of the component has a special responsibility for the
proper and safe handling of the component within their company. Only use the
component when it is in perfect operating condition in order to prevent danger to
persons and property.
This operating manual contains information that you and your employees need
for safe operation over the life of the component. Be sure to read these Operating
Instructions carefully and ensure that the measures described here are observed.
The operator's duty of care includes planning the necessary safety measures and
monitoring that these measures are observed. The following principles apply:
•Only qualified personnel may work on the component.
•The operating company must authorize personnel to carry out the relevant
tasks.
•Order and cleanliness must be maintained at the work stations and in the
entire area surrounding the component.
•Personnel must wear suitable work clothing and personal protective
equipment. As the operating company must ensure that work clothing and
personal protective equipment are used.
•Inform personnel regarding any properties of the product which might pose a
health risk and the preventative measures to be taken.
•Have a qualified first-aid representative on call during the operation. This
person must be able to initiate any necessary first-aid measures in case of an
emergency.
•Clearly define procedures, competences and responsibilities for those
working in the area of the component. Everybody must know what to do in
case of an emergency. Instruct the staff in this respect at regular intervals.
•The signs on the component must always be complete and easy to read.
Check, clean and replace the signs as necessary at regular intervals.
•Observe the Technical Data specified and the limits of use!
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 staff and by wearing personal protective equipment.
Residual dangers on the valve and measures
Danger Cause Measure
Danger to life Inadvertent switch-on of the
valve
Effectively disconnect all components, effectively prevent switch-
on.
Electric power Observe the following safety rules:
1. Isolate from the power supply.
2. Take appropriate measures to prevent switch on.
3. Test absence of voltage.
4. Earthing and short-circuiting.
5. Cover or safeguard any adjacent live parts.
Spring tension in the actuator Danger to life caused by compression spring in the actuator. Do
not open the actuator but return it to GEA Tuchenhagen for
proper disposal.
Safety
Residual dangers
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Residual dangers on the valve and measures
Danger Cause Measure
Danger of injury Danger presented by moving or
sharp-edged parts
The operator must exercise caution and prudence.
For all work:
•Wear suitable work clothing.
•Never operate the machine if the cover panels are not
correctly fitted.
•Never open the cover panels during the operation.
•Never reach into openings.
As a precautionary measure, wear personal protective equipment
in the vicinity of the valve:
•Protective gloves
•Safety shoes
Environmental damage Operating materials with
properties which are harmful to
the environment
For all work:
•Collect lubricants in suitable containers.
•Dispose of lubricants in accordance with the pertinent
regulations.
2.9 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.
•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.
Safety
Hazard Areas
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•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 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 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
Butterfly valve with control top
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3.3 Intermediate flange design – VV (788)
Fig.6
Butterfly valve design for matrix-piped systems.
3.4 Manual actuator
There are different construction designs for the manual actuator.
Standard design manual actuator
Fig.7
No. Designation
1 Standard
2 Electric feedback
Scissor grip drive
Fig.8
The scissor grip drive can position the shut-off disk in the predefined positions
around the circumference (12 x 15°).
Description
Intermediate flange design – VV (788)
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Adjustable manual operation
Fig.9
The lever on the adjustable hand drive can be continually adjusted in the range of
0° to 90°.
Description
Manual 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 or closes,
depending on the definition of the resting position. 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 butterfly valve.
3.5.2 Actuator A.1
Fig.10
The switching state is detected and indicated by the control top (B).
The visual position indication (O) can be recognized by the red marking.
3.5.3 Actuator A.2
Fig.11
Feedback of switching states can be provided by proximity switches in the
mounting bracket (1). The resting position can be reported by proximity switches
that can be attached to the mounting bracket as required.
Description
Functional description
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The visual position indication (O) can be recognized by the red marking.
3.5.4 Manual Actuator Type H
Fig.12
To open or close the valve, release the hand lever (1) by gently pulling it out of
the locking device and turning it by 90°. When the lever is released, it locks into
place in the holes provided. The limit positions of the butterfly valve can be
detected by proximity switches.
3.5.5 Butterfly Valve Body without Actuator
Fig.13
The valve disk (2) is supported between two flanges screwed together (3, 4) and
a separate plain bearing (5).
Depending on the actuator position, the valve disk is opened to different angles
and activated in the pipe opened. If the blade of the disk is parallel to the centre
axis of the pipe, the butterfly valve is located in the fully opened position and
guarantees maximum flow. When in the closed position, the blade of the valve
disk blocks the flow of the butterfly valve.
Hint!
The hole (B) in the square end and the markings on the lower shaft are
used as position indicators for the valve disk.
Description
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