GEA VARIVENT 24/7 PMO User manual

Hygienic valves
GEA VARIVENT® 24/7 PMO valve 2.0, type M/2.0
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.
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TABLE OF CONTENTS
1 General Information 7
1.1 Information on the Document 7
1.1.1 Binding Character of These Operating Instructions 7
1.1.2 Notes on the Illustrations 7
1.1.3 Symbols and Highlighting 7
1.2 Manufacturer address 8
1.3 Contact 8
1.4 EU Declaration of Conformity in accordance with the EC Machinery Directive 2006/42/EC 9
1.5 Translated copy of the EU - Declaration of conformity in accordance with the Pressure Equipment Directive
2006/42/EU 10
1.6 UK Declaration of Conformity for the Delivery of Machines (Safety) dated 2008 11
2 Safety 12
2.1 Intended use 12
2.1.1 Requirements for operation 12
2.1.2 Pressure equipment directive 12
2.1.3 ATEX directive 12
2.1.4 Improper operating conditions 13
2.2 Operator’s Duty of Care 13
2.3 Subsequent changes 14
2.4 General safety instructions and dangers 14
2.4.1 Principles for safe operation 14
2.4.2 Environmental Protection 15
2.4.3 Electrical Equipment 15
2.5 Supplementary Regulations 15
2.6 Qualification of personnel 15
2.7 Safety equipment 17
2.7.1 Signage 17
2.8 Residual dangers 18
2.9 Danger zones 19
3 Description 22
3.1 Design 22
3.2 Functional description 24
3.2.1 Leakage-Proof Shut-Off 24
3.2.2 Cleaning by lifting 24
3.2.3 Actuator Function 24
4 Transport and storage 25
4.1 Storage conditions 25
4.2 Transport 25
4.2.1 Scope of supply 26
5 Technical data 27
5.1 Type plate 27
5.2 Technical data 27
5.3 Resistance and permitted operating temperature of the sealing materials 28
5.4 Pipe ends - General table of measurements 29
5.5 Tool 30
5.6 Lubricants 31
5.7 Weights 31
6 Assembly and installation 32
6.1 Safety instructions 32
6.2 Notes on installation 32
6.3 Control head 32
6.4 Valve with Detachable Pipe Connection Elements 32
6.5 Valve with welded ends 33
6.6 Pneumatic connections 34
6.6.1 Air requirement 34
6.6.2 Establishing hose connections 34
Hose connection plan - mixproof valves M/2.0 with control top T.VIS 35
6.7 Electrical connection with T.VIS control top 36
6.7.1 Adjustment of the control top 36
Control top T.VIS A-15 adjustment 36
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Control top T.VIS M-15 adjustment 38
6.7.2 Adjustment of the initiators in the lantern 41
Fitting the sliding piece 41
Set the slider 42
Fitting the proximity switch 43
Set the proximity switch 43
6.8 Test procedure according to PMO for valve type M/ 2.0 45
6.8.1 Test procedure 45
6.8.2 Hardware description 46
7 Start-up 48
7.1 Safety instructions 48
7.2 Notes on commissioning 48
8 Operation and control 49
8.1 Safety instructions 49
8.2 Feedback system / signal analysis 49
9 Cleaning 50
9.1 Cleaning 50
9.1.1 Cleaning Process Examples 50
9.1.2 Cleaning effect 50
9.1.3 Cleaning the leakage outlet of the mixproof valve type M/ 2.0 51
9.1.4 Cleaning of the lower balancer 51
9.1.5 Examples for cleaning by lifting 51
9.2 Passivation 51
10 Maintenance 53
10.1 Safety instructions 53
10.2 Inspections 54
10.2.1 Product contact seals 54
10.2.2 Pneumatic connections 54
10.2.3 Electrical connections 55
10.3 Maintenance intervals 55
10.4 Prior to removal 56
10.5 Disassembly 56
10.5.1 Start disassembly 56
10.5.2 Removing the control top 60
10.5.3 Disconnecting the valve from the housing 61
10.5.4 Removing the valve disk 63
10.5.5 Dismantle double-disk 64
10.5.6 Dismantle lifting actuator 65
10.5.7 Disassembly sterile lock 67
10.5.8 Disassembly balancer plug 67
10.6 Installation 68
10.6.1 Tightening torques 69
10.6.2 Fitting the lifting actuator 69
10.6.3 Installing the valve 72
10.6.4 Mount the switch bar and control top 77
10.6.5 Assembly balancer plug 78
10.6.6 Fit the sterile lock 78
10.6.7 Installing the valve in the housing 79
10.6.8 Checking the function 82
Checking the valve stroke 82
Check the lift stroke 82
10.7 Maintenance 82
10.7.1 Cleaning the valve 82
10.7.2 Replacing Seals 83
Replacing V-Ring RA on the double-disk and valve disk 83
Replace more seals 85
Lubricating seals and threads 85
11 Alarms 88
11.1 Malfunctions and remedies 88
12 Decommissioning 89
12.1 Safety instructions 89
12.2 Disposal 89
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12.2.1 General notes 89
12.2.2 Valve Actuator Disposal 89
13 Spare parts list - mixproof valve M/2.0 with cleaning of lower balancer 90
14 Spare parts list - mixproof valve M/2.0 without cleaning of lower balancer 95
15 Spare parts list - Lifting actuator M/2.0 100
16 Dimension sheet - mixproof valve type M/ 2.0 103
17 Appendix 105
17.1 Lists 105
17.1.1 Abbreviations and terms 105
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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
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: Valve with actuator
Type: VARIVENT®
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:
EN ISO 12100: 2010
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 Buchen, Germany
Büchen, 24 January 2020
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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1.6 UK Declaration of Conformity for the Delivery of Machines (Safety) dated 2008
1/1
UK- Declaration of Conformity by Supply of Machinery (Safety) Regulations 2008
Manufacturer:
GEA Tuchenhagen GmbH
Am Industriepark 2-10
21514 Büchen, Germany
Hereby, we declare that the machine designated in the following
Designation:
Valve with actuator
Type:
VARIVENT®
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 UK legislation:
Supply of Machinery (Safety) Regulations 2008
Applicable harmonized standards, in
particular:
EN ISO 12100: 2010
Safety of machinery - General principles for design
- Risk assessment and risk reduction
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.
GEA Importer into UK:
GEA Mechanical Equipment UK Ltd
Westfalia House
Old Wolverton Road, Old Wolverton, Milton Keynes
MK12 5PY, United Kingdom
Person authorised for compilation and handover of technical
documentation:
Michael Kiely
GEA Mechanical Equipment UK Ltd
Westfalia House
Old Wolverton Road, Old Wolverton, Milton Keynes
MK12 5PY, United Kingdom
Büchen, 14 March 2023
________________________________ ________________________________
Franz Bürmann i.V. Matthias Südel
Managing Director Senior Director Engineering
General Information
UK Declaration of Conformity for the Delivery of Machines (Safety) dated 2008
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2 Safety
2.1 Intended use
The mixproof valve type 24/7 M/2.0 PMO is used for the mix-proof shut-off of
high-grade, non-abrasive products at intersection points in pipe systems. It is
resistant to pressure surges in its closed state.
Hint!
Do not install the valve in spring-opening, as this will open when there
is a current or air failure and leads to product mixing.
In a closed pipe system, hydraulic pressure build-up may occur when the valve
switches and result in seal damage.
The mixproof valve type 24/7 M/2.0 PMO is intended for installation in a milk-
processing plant in accordance with the Pasteurized Milk Ordinance (PMO)
section 7, item 15p. (B) and complies with the 3-A standard 85-03 for mixproof
valves. The function enables the safe separation of milk / milk products and
cleaning or disinfecting solutions and, according to PMO section 1 15p.B permits
the seat cleaning of the valve seats while milk is in the opposite housing.
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 2014/68/EU. Classified according to
Annex II in category 1.
According to the scope of directive 2014/34/EC, article 1, paragraph 2, f, the
exception of the directive applies, due to conformity with the machine directive
2006/42/EU.
The nominal diameters smaller than DN 25 are subject to article 4, paragraph 3
of the Pressure Equipment Directive which specifies sound engineering practice.
Nominal diameters ≥ IPS 4“; DN 125 valid for the fluid group II.
In the event of any deviations, GEA Tuchenhagen GmbH will supply a specific
Declaration of Conformity.
2.1.3 ATEX directive
Safety
Intended use
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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.
•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.
Safety
Operator’s Duty of Care
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•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
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.
Safety
Subsequent changes
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•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.
•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,
Safety
Supplementary Regulations
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•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.
•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:
Safety
Qualification of personnel
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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.
The signs and notes on the valve 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.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 Danger zones
Please observe the following notes:
Safety
Danger zones
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Fig.4: Danger zones
•In the event of malfunctions, shut down the valve (disconnect from the power
and air supply) and secure it against being used.
Safety
Danger zones
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