GEA VARIVENT Y User manual

Hygienic valves
GEA VARIVENT® Valve Type Y
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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SYMBOLS USED
Danger
Stands for an immediate danger which leads to heavy physical injuries
or to the death.
Warning!
Stands for a possibly dangerous situation which leads to heavy
physical injuries or to the death.
Caution!
Stands for a possibly dangerous situation which could lead to light
physical injuries or to damages to property.
Hint!
Stands for an important tip whose attention is important for the
designated use and function of the device.
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LAYOUT INFORMATION
Bullet points and numbered list characters
Bullet points are used to separate logical contents within a section:
•Bullet point 1
Types of bullet point 1.
•Bullet point 2
Types of bullet point 2.
Numbered list characters are used to separate enumerations within a
descriptive text:
Descriptive text with consecutive numbering:
–Numbered list point 1
–Numbered list point 2
Handling instructions
Handling instructions require you to do something. Several consecutive steps
result in a handling sequence that should be run in the specified order. The
handling sequence can be divided into separate steps.
Handling sequence
1. Handling sequence step 1
–step 1,
–step 2,
–step 3.
2. Handling sequence step 2
The subsequent handling sequence is the expected result:
®Result of the handling sequence.
Individual handling steps
Individual handling steps are marked thus:
–Individual work steps
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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 for Machines 9
2 Safety 10
2.1 Intended use 10
2.1.1 Requirements for operation 10
2.1.2 Pressure equipment directive 10
2.1.3 ATEX directive 10
2.1.4 Improper operating conditions 10
2.2 Operator’s Duty of Care 11
2.3 Subsequent changes 11
2.4 General safety instructions and dangers 12
2.4.1 Principles for safe operation 12
2.4.2 Environmental Protection 12
2.4.3 Electrical Equipment 13
2.5 Supplementary Regulations 13
2.6 Qualification of Staff 13
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 19
3.2.1 Opening and closing the valve 19
3.2.2 Actuator Function 20
3.2.3 Leakage-Proof Shut-Off 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 of Sealing Materials 26
5.5 Pipe ends - General table of measurements 27
5.6 Tool 29
5.7 Lubricants 29
5.8 Weights 29
6 Assembly and installation 31
6.1 Safety instructions 31
6.2 Notes on installation 31
6.3 Control head 31
6.4 Valve with Detachable Pipe Connection Elements 31
6.5 Valve with Welded Ends 32
6.6 Pneumatic connections 33
6.6.1 Air Requirement 33
6.6.2 Establishing Hose Connections 33
6.7 Electrical connection with T.VIS control top 34
7 Start-up 35
7.1 Safety instructions 35
7.2 Notes on commissioning 35
8 Operation and control 36
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8.1 Safety instructions 36
9 Cleaning 37
9.1 Cleaning 37
9.1.1 Cleaning Process Examples 37
9.1.2 Cleaning effect 37
9.1.3 Cleaning the Leakage Cavity 38
9.2 Passivation 38
10 Maintenance 39
10.1 Safety instructions 39
10.2 Inspections 40
10.2.1 Product contact seals 40
10.2.2 Pneumatic connections 40
10.2.3 Electrical connections 40
10.3 Maintenance intervals 41
10.4 Prior to disassembly 41
10.5 Disassembling the Valve 41
10.5.1 Supplemental disc removal 42
10.5.2 Removing the T.VIS M-15 Control Top 43
10.5.3 Removing the T.VIS A-15 Control Top 44
10.5.4 Disconnecting the Valve from the Housing 44
10.5.5 Separating the valve from the drive 45
10.5.6 Separating the valve and the lamp 46
10.5.7 Disassembly of the valve insert. 47
10.6 Maintenance 47
10.6.1 Cleaning the Valve 47
10.6.2 Replacing the V-Ring 48
10.6.3 Lubricating Seals and Threads 50
10.7 Installation 51
10.7.1 Spring 51
10.7.2 Cleaning hood 51
10.7.3 Place the seating ring between the housings 52
10.7.4 Installing the valve into the housing 52
10.7.5 Checking assembly 52
10.7.6 Reconnect the cleaning hose 53
10.7.7 Torques for the Clamps and Clamp Connections 54
10.7.8 Valve Stroke 55
11 Alarms 57
11.1 Malfunctions and remedies 57
12 Decommissioning 58
12.1 Safety instructions 58
12.2 Disposal 58
12.2.1 General notes 58
12.2.2 Valve Actuator Disposal 58
13 Spare parts list - dual seat two-way valve Y 59
14 Appendix 72
14.1 Lists 72
14.1.1 Abbreviations and terms 72
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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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2 Safety
2.1 Intended use
The double-seat change-over valve Y is used for switching liquid flows in pipeline
systems
The medium should preferably flow in the opening direction of the valve disk to
avoid pipe hammers when the valve is opened or closed.
If the valve is used in the opposite direction (valve closing), a damping cylinder
can be used to avoid pressure drops.
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 of such misuse lies entirely with
the operator of the facility.
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) as defined in
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 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”.
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 reliability of the valve cannot be ensured under improper
operating conditions. Therefore avoid improper operating conditions.
Safety
Intended use
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Operating the valve 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 valve.
•Damage has been detected on the valve.
•Maintenance intervals have been exceeded.
2.2 Operator’s Duty of Care
In your capacity as operator of the facility you bear a particular responsibility for
the proper and safe handling of the valve in your facility. Only use the valve when
it is in perfect condition to prevent danger to persons and property.
These Operating Instructions contain the information you and your staff need for
the safe and reliable operation during the entire service life of the valve. 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 allow qualified staff to work on the valve.
•The operator must authorize the staff to carry out the relevant tasks.
•Working areas and the entire environment of the valve must be neat and
clean.
•The staff must wear suitable work clothing and personal protective equipment.
As the operator of the facility make sure that work clothing and personal
protective equipment are used.
•Instruct the staff with regard to any properties of the product which might pose
a health risk and the preventative measures to be taken.
•Have a qualified first-aider on call during the operation, who can initiate the
necessary first-aid measures in case of an emergency.
•Clearly define processes, lines of authority and responsibilities associated
with the valve. Everybody must know what to do in case of an emergency.
Instruct the staff in this respect at regular intervals.
•The signs relating to the valve must always be complete and legible. 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
Safety
Operator’s Duty of Care
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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 Tuchenhagen GmbH
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.
•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.
Safety
General safety instructions and dangers
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•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 Staff
This section contains information about the qualifications that staff working on the
valve must have.
Operating and maintenance staff 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 staff to carry out any work on explosion-protected
equipment. 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:
•Vocational training as a specialist who can work on the valve independently.
•Sufficient instruction to work on the valve under the supervision and direction
of a qualified specialist.
Each member of staff must meet the following requirements to be allowed to work
on the valve:
•Personal qualification for the relevant task.
Safety
Supplementary Regulations
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•Sufficient professional qualification for the relevant task.
•Instructed with regard to the function of the valve.
•Instructed with regard to the operating sequences of the valve.
•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.
For work to be carried out on the valve the following user groups are
distinguished:
User groups
Staff Qualifications
Operating staff Adequate instruction and sound knowledge in the following areas:
•Function of the valve
•Valve operating sequences
•What to do in case of an emergency
•Lines of authority and responsibilities with respect to the task
Maintenance staff Adequate instruction as well as sound knowledge of the design
and function of the valve.
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 Hazard Areas
Fig.4
Please observe the following notes:
•In the event of malfunctions, shut down the valve (disconnect from the power
and air supply) and secure it against being used.
•Never reach into the lantern (9) or the valve housing (401) when the valve is
switching. Fingers can be crushed or cut off.
Safety
Hazard Areas
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•On a spring-closing valve there is danger of injury when the clamp
connections (43.1/43.2) are opened, as the released spring pretension will
suddenly lift the actuator. Therefore, release the spring tension before
detaching the clamp connections (43.1/43.2) by supplying the actuator (A)
with compressed air.
•Before starting any service, maintenance or repair work, disconnect the valve
from the power supply and secure it against inadvertently being switched
back on again.
•Only allow a qualified electrician to carry out any work on the electrical power
supply.
•Check the electrical equipment of the valve at regular intervals. Immediately
remedy loose connections and molten cables.
•If work on live parts cannot be avoided, call in a second person, who can
operate the main switch in case of an emergency.
•The housing sockets have very sharp edges. When transporting and
assembling the valve be sure to wear suitable protective gloves.
•When the valve switches, when the valve seat is being cleaned or if a seal is
defective, cleaning medium exits from the leakage outlet of the rinsing valve.
Collect this liquid in a suitable container such as a funnel or a drip pan and
discharge it in a safe manner. Observe the instructions in the safety data
sheets issued by the cleaning agent manufacturers.
Safety
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3 Description
3.1 Design
Fig.5
Design
No. Designation No. Designation
A Actuator 11 Cleaning hood
B T.VIS control top 15 Valve disk
1 Seal 16 Double-disk
2 Bearing 17 Additional disc
3 Sealing disk 22 Air connection
4 Bearing disk 24 Electrical connection
9 Lantern
Description
Design
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3.2 Functional description
3.2.1 Opening and closing the valve
Fig.6
Opening of valve
In the closed setting, the upper and lower housings are sealed by a double-
seated disc (16). Throttle gaps limit the leakage in case of seal defects, even on
both seals. The additional disc (17) is opened. The valve is enacted by air
pressure through the air connection. The piston of the actuation cylinder presses
up against the spring. The actuated lower valve disc is pulled up in a few-
millimetres stroke and the cavity between the upper and lower valve discs is
blocked by the upper disc orientation, using the middle seals to block against the
product space.
The valve disc combination moves up into the final position and opens the valve.
With the same motion, the additional disc (17) is pulled up and blocks both lower
housings off.
Description
Functional description
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Closing the valve
The closing process happens in the opposite sequence, therefore the upper
valve seals are first seated before the lower valve seals leave the middle seal
and the lower disc closes. With the downward motion of the valve rod, the
additional disc is opened again.
3.2.2 Actuator Function
The actuator is of the spring-closing type (Z). The valve is closed in the non-
actuated position.
Identification on the T.VIS control top once the installation (SET-UP) has been
completed:
•Green steady light (1): valve in non-actuated position
•Yellow steady light (1): valve in end position (actuated position)
Fig.7
3.2.3 Leakage-Proof Shut-Off
Fig.8
Description
Functional description
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