GEA VARIVENT DN 25 User manual

Hygienic valves
GEA VARIVENT® Double-Seat Valve Type R
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 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 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 personnel 12
2.7 Safety equipment 14
2.7.1 Signage 14
2.8 Residual dangers 15
2.9 Hazard Areas 16
3 Description 18
3.1 Design 18
3.2 Functional description 20
3.2.1 Leakage-Proof Shut-Off 20
3.2.2 Cleaning function 20
3.2.3 Actuator Function 20
4 Transport and storage 22
4.1 Storage conditions 22
4.2 Transport 22
4.2.1 Scope of supply 23
5 Technical data 24
5.1 Type plate 24
5.2 Technical data 24
5.3 Cleaning connection 25
5.4 Resistance and permitted operating temperature of the sealing materials 26
5.5 Pipe ends - General table of measurements 27
5.6 Tool 28
5.7 Lubricants 29
5.8 Weights 29
6 Assembly and installation 30
6.1 Safety instructions 30
6.2 Notes on installation 30
6.3 Control head 30
6.4 Valve with Detachable Pipe Connection Elements 30
6.5 Valve with welded ends 31
6.6 Pneumatic connections 32
6.6.1 Air Requirement 32
6.6.2 Establishing Hose Connections 32
6.7 Electrical connection with T.VIS control top 33
7 Start-up 34
7.1 Safety instructions 34
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7.2 Notes on commissioning 34
8 Operation and control 35
8.1 Safety instructions 35
9 Cleaning 36
9.1 Cleaning 36
9.1.1 Cleaning Process Examples 36
9.1.2 Cleaning effect 36
9.1.3 Cleaning the Leakage Cavity 37
9.2 Passivation 37
10 Maintenance 38
10.1 Safety instructions 38
10.2 Inspections 39
10.2.1 Product contact seals 39
10.2.2 Pneumatic connections 39
10.2.3 Electrical connections 39
10.2.4 Signs on the valve 40
10.3 Maintenance intervals 40
10.4 Prior to disassembly 40
10.5 Disassembly 41
10.5.1 Start disassembly 41
10.5.2 Removing the control top 42
10.5.3 Disconnecting the Valve from the Housing 44
10.5.4 Disassembling the Valve into Individual Parts 44
10.5.5 Disassembly balancer plug 45
10.5.6 Disassembly of the housing combination 46
10.6 Installation 46
10.6.1 Torques for the clamps and clamp connections 46
10.6.2 Assembling the valve from individual parts 46
10.6.3 Fitting the control top 48
10.6.4 Assembly of the housing combination 49
10.6.5 Assembly balancer plug 50
10.6.6 Installing the valve insert in the housing 52
10.6.7 Checking the function 53
10.7 Maintenance 54
10.7.1 Cleaning the valve 54
10.7.2 Replacing Seals 55
Replacing V-Ring double-disk 55
Replacing V-Ring RA valve disk 57
Replace more seals 58
10.7.3 Lubricating seals and threads 59
11 Alarms 61
11.1 Malfunctions and remedies 61
12 Decommissioning 62
12.1 Safety instructions 62
12.2 Disposal 62
12.2.1 General notes 62
12.2.2 Valve Actuator Disposal 62
13 Spare parts list - Double seat valve R 63
14 Dimension sheet - VARIVENT® double seat valve R 75
15 Appendix 77
15.1 Lists 77
15.1.1 Abbreviations and terms 77
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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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2 Safety
2.1 Intended use
The mixproof valve R 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.
Hint!
The manufacturer will not accept any liability for damage resulting
from any use of the valve which is not in accordance with the
designated use of the valve. The risk is borne solely by the operating
company.
2.1.1 Requirements for operation
The prerequisite for reliable and safe operation of the component is proper
transportation and storage as well as professional installation and assembly.
Operating the unit within the limits of its designated use also involves adhering to
the operating, inspection and maintenance instructions.
2.1.2 Pressure equipment directive
The valve is a piece of pressure equipment (without safety function) in the sense
of the pressure equipment directive 2014/68/EU: They are classified according to
Annex II in category 1.
According to the scope of directive 2014/64/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 DN25 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
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”.
Safety
Intended use
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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.
•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.
Safety
Operator’s Duty of Care
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