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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