GEA VARIVENT TSVN User manual

Hygienic valves
GEA VARIVENT® Sampling valve type TSVN and TSVN
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
2.2 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
Safety instructions 11
2.4.2 Environmental Protection 11
2.4.3 Electrical Equipment 12
2.5 Supplementary Regulations 12
2.6 Qualification of personnel 12
2.7 Safety equipment 13
2.7.1 Signs 13
3 Transport and storage 15
3.1 Scope of supply 15
3.2 Transport 15
3.3 Storage conditions 15
4 Technical data 16
4.1 Type plate 16
4.2 Technical data 16
4.3 Resistance and permitted operating temperature of the sealing materials 17
4.4 Pipe ends (R) 19
4.5 Lubricants 19
5 Description 20
5.1 Design of the valve 20
6 Assembly and installation 22
6.1 Safety instructions 22
6.2 Notes on installation 22
6.3 Valve with Detachable Pipe Connection Elements 22
6.4 Welding In a Valve with Pipe Connection 23
6.4.1 Valve with Welded Ends 23
7 Start-up 25
7.1 Safety instructions 25
7.2 Commissioning activities 25
8 Cleaning and Passivation 26
8.1 Cleaning 26
8.1.1 Cleaning Process Examples 26
8.1.2 Cleaning effect 26
8.2 Passivation 27
9 Maintenance 28
9.1 Safety instructions 28
9.2 Inspections 29
9.3 Maintenance intervals 29
9.4 Prior to removal 30
9.5 Disassembling the Valve 30
9.5.1 Removing the valve 31
9.5.2 Removing the valve disk 31
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Valve TSVU without bellows 32
Valve TSVU with bellows 33
9.5.3 Removing the handwheel 33
Valve TSVN 33
Valve TSVU 34
9.6 Maintenance 35
9.6.1 Cleaning the valve 35
9.6.2 Replacing seals 35
9.6.3 Lubricating seals and threads 35
9.7 Installation 37
9.7.1 O-Ring on the valve disk 37
9.7.2 Fitting the piston 37
9.7.3 Fitting position 37
10 Alarms 38
10.1 Malfunctions and remedies 38
11 Decommissioning 39
11.1 Safety precautions 39
11.2 Disposal 39
11.2.1 General notes 39
12 Appendix 40
12.1 Lists 40
12.2 Abbreviations and terms 40
13 Spare parts list - Sampling valve TSVN" 42
14 Dimension sheet - VARINLINE® Sampling valve, type TSVN 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 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 sampling valve TSVN/TSVU is intended for taking 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 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.
2.2 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.
Safety
Intended use
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•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
You should never make any technical modifications to the valve. 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 Aseptomag AG should be
fitted. This ensures the reliable and economical operation of the valve.
2.4 General safety instructions and dangers
The valve is operationally reliable. It was built according to state-of-the-art
science and technology.
Nevertheless, the valve can pose dangers, especially if
•the valve is not used in accordance with its intended use,
•the valve is not used correctly,
•the valve is operated under impermissible operating 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.
Safety
Subsequent changes
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•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.
2.4.1.1 Safety instructions
Dangerous situations during operation can be avoided by safety-conscious and
proactive behaviour of the personnel.
For operation, the following principles apply:
•Monitor the component during operation.
•Safety devices must not be changed, removed or taken out of service. Check
all safety devices at regular intervals.
•All guards and hoods must be fitted as intended.
•The installation location of the component must always be properly ventilated.
•Structural changes to the component are not permitted. Report any changes
to the component immediately to the person in charge.
•Always keep danger zones clear. Do not leave any objects in the danger
zone. Only allow persons to enter the danger zone when the machine is de-
energized.
•Regularly check that all emergency stop devices are working correctly.
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.
Safety
General safety instructions and dangers
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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:
•Personal suitability for the respective task.
•Sufficient professional qualification for the respective task.
•Received instruction about the functionality of the component.
Safety
Supplementary Regulations
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•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 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 Transport and storage
3.1 Scope of supply
On receipt of the valve check whether
•the details on the type plate correspond to the data in the order and delivery
documents,
•the equipment is complete and all components are in good order.
3.2 Transport
For transport, the following principles apply:
•Only use approved, fully functional means of transport, lifting gear and slings
that are suitable for the purpose to transport the package units/valves.
Observe the maximum load-bearing capacities.
•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.
•Only allow qualified staff to transport the valve.
•Movable parts must be properly secured.
•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.
3.3 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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4 Technical data
4.1 Type plate
The type plate clearly identifies the valve.
Fig.4: Type plate
The type plate provides the following key data:
Key data of the valve
Type Sampling Valve TSVN
Serial Serial number
Material EPDM (FDA)
Control air pressure bar/psi min. 6.0 / 87; max. 8.0 / 116
Product pressure bar/psi max. 10.0 / 145
4.2 Technical data
Refer to the following tables for the key technical data of the valve:
Technical data: valve
Designation Description
Size DN 32/25
DN 50/40
Material of product contact parts Stainless steel 1.4404
Max. temperature PTFE O-ring (7)
material no. 930-464 + 150 °C when flaming
Fitting position Suspended
Technical data
Type plate
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Technical data: temperatures
Designation Description
Ambient temperature
0 to 60 °C (32 ... 140 °F), standard
< 0 °C Use control air with low dew
point, protect valve stems from icing
up
Product temperature and operating
temperature depending on the sealing material
Technical data: pressure
Designation Description
Product pressure max. 10 bar (145 psi), standard
Control air pressure 6 bar, max. 8 bar
Air requirement 13.1 cm3/stroke
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
4.3 Resistance and permitted operating temperature of the sealing materials
The resistance and permitted operating temperature of the sealing materials
depend 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.
The maximum operating temperature is defined by the sealing type and its
mechanical load.
Due to the versatile conditions of use (e.g. usage duration, switching frequency,
type and temperature of product and cleaning agents as well as usage
environment), GEA Tuchenhagen recommends that the user carries out
resistance tests.
Resistance:
•+ = good resistance
•o = reduced resistance
Technical data
Resistance and permitted operating temperature of the sealing materials
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•– = no resistance
Table of sealing resistance / permitted operating temperature
Medium
Maximum
operating
temperatures
Sealing materials
EPDM FKM HNBR PTFE
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 +
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
Table sealing materials - temperature resistance
Sealing materials General temperature resistance*
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)
* The general resistance of the material does not correspond to the maximum
operating temperature
Technical data
Resistance and permitted operating temperature of the sealing materials
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4.4 Pipe ends (R)
Fig.5: Sampling valve TSVN: I-Line_Housing (I), pipe ends (R)
Dimensions for tubes in DN
Size TSVN/TSVU Pipe ends (R)
Dimensions Size
50/40 19x1.5 DN15
35/25 13x1.5 DN10
4.5 Lubricants
Lubricants
Designation Material no.
Rivolta F.L.G. MD-2 413-071
PARALIQ GTE 703 413-064
Technical data
Pipe ends (R)
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5 Description
5.1 Design of the valve
Fig.6: Main components on the valve
Key
No. Designation
1 Seal ring
2 Seal disk
8 Sampling housing
9 Sampling lantern
15 Valve disk
16 Piston rod
Description
Design of the valve
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