GEA VARIVENT Series User manual

Hygienic valves
GEA VARIVENT Sampling Valve Type I
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
1.5 EC - Declaration of conformity in accordance with the Pressure Equipment Directive 2014/68/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 Improper operating conditions 9
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 11
2.4.2 Environmental Protection 11
2.4.3 Electrical Equipment 11
2.5 Supplementary Regulations 12
2.6 Qualification of personnel 12
2.7 Safety equipment 13
2.7.1 Signs 13
3 Description 15
3.1 Design of the valve 15
4 Transport and storage 16
4.1 Scope of supply 16
4.2 Transport 16
4.3 Storage conditions 16
5 Technical data 17
5.1 Type plate 17
5.2 Technical data 17
5.3 Resistance of the sealing materials 18
5.4 Pipe ends - General table of measurements 19
5.5 Lubricants 20
6 Assembly and installation 21
6.1 Safety instructions 21
6.2 Notes on installation 21
6.3 Valve with Detachable Pipe Connection Elements 21
6.4 Valve with Welded Ends 22
7 Start-up 23
7.1 Safety instructions 23
7.2 Notes on commissioning 23
8 Operation and control 24
8.1 Safety instructions 24
9 Cleaning and Passivation 25
9.1 Cleaning 25
9.1.1 Cleaning Process Examples 25
9.1.2 Cleaning effect 25
9.2 Passivation 26
10 Maintenance 27
10.1 Safety instructions 27
10.2 Inspections 28
10.3 Maintenance intervals 28
10.4 Prior to removal 29
10.5 Disassembling the Valve 29
10.5.1 Removing the valve disk 30
10.5.2 Removing the handwheel 30
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10.6 Maintenance 31
10.7 Installing the valve 32
11 Alarms 33
11.1 Malfunctions and remedies 33
12 Decommissioning 34
12.1 Safety precautions 34
12.2 Disposal 34
12.2.1 General notes 34
13 Parts list - sampling valve I 35
14 Appendix 45
14.1 Lists 45
14.2 Abbreviations and terms 45
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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: VARIVENT®
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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1.5 EC - Declaration of conformity in accordance with the Pressure Equipment
Directive 2014/68/EU
Manufacturer:
GEA Tuchenhagen GmbH
Am Industriepark 2-10
21514 Büchen
We hereby declare that the product series designated below, based on their design, type and version brought
to market by us, complies with the basic health and safety requirements of the Pressure Equipment Directive.
This declaration will become invalid if any alterations are made to the pressure equipment which have not
been agreed with us.
Product series: VARIVENT®, ECOVENT®, VARINLINE®
Serial numbers: 140000 - 169999
Relevant EC directives: 2014/68/EU Pressure Equipment Directive
Category I
Conformity assessment
procedure
(Internal production control)
Applicable harmonized standards,
in particular:
DIN EN 13445-3:2014-12 Experimental methods (burst test)
Other applied standards and
technical specifications:
DIN EN 10088-1
DIN EN 10088-2
DIN EN 10088-3
DIN EN 12516
Materials standard
Industrial valves - Shell design
strength
Remarks: –Valid for substances of fluid group 2.
If substances of fluid group 1 are used, a new
assessment must be carried out.
–The nominal diameters DN25, 1”OD and smaller
are subject to article 4, paragraph 3 of the
Pressure Equipment Directive which specifies
sound engineering practice.
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, 08/11/2017
Matthias Südel
Senior Director
Product Development Flow Components
Michael Wulle
Managing Director
General Information
EC - Declaration of conformity in accordance with the Pressure Equipment Directive 2014/68/EU
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2 Safety
2.1 Intended use
The sampling valve type I is intended for drawing samples of liquids and viscous
media.
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 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.
•Clamp connections or screw fastenings on the housing are not properly
fastened and secured against accidental loosening.
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.
Safety
Intended use
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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.
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
Safety
Subsequent changes
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•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.
•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.
Safety
General safety instructions and dangers
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•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:
•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.
Safety
Supplementary Regulations
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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 Signs
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
Explosion-hazarded zones warning
Safety
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3 Description
3.1 Design of the valve
Fig.4: Main components on the valve
Key
No. Designation
1 Seal ring
2 Bearing
9 Lantern
15 Valve disk
20 Handwheel
21 Switching disk
28 Clamp
31 Housing
Description
Design of the valve
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4 Transport and storage
4.1 Scope of supply
On receipt of the valve check whether
•the details on the main valve components correspond to the data in the order
and delivery documents,
•the equipment is complete and all components are in good order.
4.2 Transport
For transport, the following principles apply:
•Only use suitable lifting gear and slings for transporting the package units/
valves.
•Observe the pictograms on the package.
•Handle valves with care to avoid damage caused by impact or careless
loading and unloading. The outside synthetic materials are susceptible to
breaking.
•Control tops (if fitted) must be protected from animal and vegetable fats.
•Only allow qualified staff to transport the valve.
•Movable parts must be properly secured.
•Only use approved, fully functional load lifting devices and lifting accessories
which are suitable for the intended purpose. Observe the maximum load-
bearing capacities.
•Secure the valve against slipping. Take the weight of the valve into account
and the position of the point of gravity.
•Under no circumstances should anyone stand under a suspended load.
•Take care when transporting the valve. Do not grip sensitive parts of the unit
to lift or push the unit or to support yourself. Avoid putting the unit down with a
jerk.
4.3 Storage conditions
The valves, valve inserts or spare parts should be stored in a dry place, free of
vibrations and dust, and protected from light. To avoid damage, leave the
components in their original packaging if possible.
If, during transport or storage, the valve is going to be exposed to temperatures ≤
0°C, it must be dried beforehand and suitable measures must be taken to protect
it from damage.
Hint!
We recommend that the valve should be stored at a temperature of ≥ 5
°C for a period of 24 hours prior to any handling (disassembling the
housings / activation of actuators) so that any ice crystals formed by
condensation water can melt.
Transport and storage
Scope of supply
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5 Technical data
5.1 Type plate
The type plate clearly identifies the valve.
Fig.5: Type plate
The type plate provides the following key data:
Key data of the valve
Type Control valve type I
Serial Serial number
Material 1.4404 (AISI316L) / EPDM (FDA)
Control air pressure bar/psi max. 8.0 / 116
Product pressure bar/psi 5.0 / 72.5
5.2 Technical data
Refer to the following tables for the key technical data of the valve:
Technical data: Valve
Designation Description
Size
DN 10 to DN 125
1" to 4" OD
2" to 6" IPS
Material of product contact parts Stainless steel 1.4404
Fitting position Vertical
Technical data: Ambient temperatures
Designation Description
Max. temperature PTFE O-ring (7)
material no. 930-464 during flaming + 150 °C (302 °F)
Ambient temperature 0 to 60 °C (32 ... 148 °F), standard
Product temperature and operating
temperature depending on the sealing material
Technical data
Type plate
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Technical data: Compressed air supply
Designation Description
Product pressure 5 bar (72.5 psi) standard
max. 10 bar (116 psi)
Control air pressure 6 bar, max. 8 bar
Control air acc. to ISO 8573-1
- Solid particle content:
Quality class 6
Particle size max. 5 µm
Particle density max. 5 mg/m3
- Water content:
Quality class 4
max. dew point +3 °C
If the unit is used at higher altitudes or
at low ambient temperatures, the dew
point must be adapted accordingly.
- Oil content: Quality class 3, ideally oil-free, max.
1 mg oil for 1 m3 air
5.3 Resistance of the sealing materials
The resistance of sealing materials depends on the type and temperature of the
medium conveyed. The exposure time can adversely affect the service life of the
seals. The sealing materials comply with the regulations of FDA 21 CFR
177.2600 or FDA 21 CFR 177.1550.
Resistance:
•+ = good resistance
•o = reduced resistance
•- = no resistance
* Depending on the installation conditions
Seal resistance for EPDM, FKM, HNBR, PTFE
Medium Temperature Sealing material (general operating temperature*)
EPDM
-40...+135 °C *
(-40...275 °F)
FKM
-10...+200 °C *
(+14...+392 °F)
HNBR
-25...+140 °C *
(-13...+284 °F)
PTFE
-200...+260 °C
(-328...+500°F)
Alkalis up to 3% up to 80 °C (176 °F) + o + +
Alkalis up to 5% up to 40 °C (104 °F) + o o +
Alkalis up to 5% up to 80 °C (176° F) + – – +
Alkalis more than
5% o – – +
Inorganic acids up
to 3% up to 80 °C (176 °F) + + + +
Inorganic acids up
to 5% up to 80 °C (176 °F) o + o +
Technical data
Resistance of the sealing materials
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Seal resistance for EPDM, FKM, HNBR, PTFE
Medium Temperature Sealing material (general operating temperature*)
EPDM
-40...+135 °C *
(-40...275 °F)
FKM
-10...+200 °C *
(+14...+392 °F)
HNBR
-25...+140 °C *
(-13...+284 °F)
PTFE
-200...+260 °C
(-328...+500°F)
Inorganic acids up
to 5%
up to 100 °C (212
°F) – + – +
Water up to 80 °C (176 °F) + + + +
Steam up to 135 °C (275°
F) + o o +
Steam, approx. 30
min
up to 150 °C (320
°F) + o – +
Fuels/hydrocarbons – + + +
Product with a fat
content of max. 35% + + + +
Product with a fat
content of more
than 35%
– + + +
Oils – + + +
* Depending on the
installation
conditions
5.4 Pipe ends - General table of measurements
Hint!
Not every valve is available in every size. Particulars of available sizes
of valves see Section 5.2, Page 17.
Dimensions for tubes in DN
Metric DN Outside
diameter
Wall
thickness
Inside
diameter
Outside
diameter acc.
to DIN 11850
25 29 1.5 26 x
40 41 1.5 38 x
50 53 1.5 50 x
65 70 2.0 66 x
80 85 2.0 81 x
100 104 2.0 100 x
125 129 2.0 125 x
150 154 2.0 150 x
Technical data
Pipe ends - General table of measurements
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Dimensions for tubes in Inch OD
Inch OD Outside
diameter
Wall
thickness
Inside
diameter
Outside
diameter acc.
to BS 4825
1" 25.4 1.65 22.1 x
1.5" 38.1 1.65 34.8 x
2" 50.8 1.65 47.5 x
2.5" 63.5 1.65 60.2 x
3" 76.2 1.65 72.9 x
4" 101.6 2.11 97.38 x
6" 152.4 2.77 146.86 x
Dimensions for tubes in Inch IPS
Inch IPS Outside
diameter
Wall
thickness
Inside
diameter
Outside
diameter
according to
DIN EN ISO
1127
2" 60.3 2 56.3 x
3" 88.9 2.3 84.3 x
4" 114.3 2.3 109.7 x
6" 168.3 2.77 162.76 x
5.5 Lubricants
Lubricants
Designation Material no.
Rivolta F.L.G. MD-2 413-071
PARALIQ GTE 703 413-064
Technical data
Lubricants
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