GEA VARICOVER MST 3A User manual

Hygienic components
Operating instruction (Translation from the original language)
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GEA VARICOVER® Pig Cleaning Station MST 3A

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 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 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 12
2.4.2 Environmental Protection 12
2.4.3 Electrical Equipment 12
2.5 Supplementary Regulations 13
2.6 Qualification of personnel 13
2.7 Safety equipment 14
2.7.1 Signage 14
2.8 Residual dangers 15
2.9 Danger zones 16
3 Description 19
3.1 Design 19
3.2 Functional description 20
3.2.1 Pig cleaning station 20
Production 20
Sending the pig 20
Receiving the pig 22
Cleaning the pig cleaning station 23
3.2.2 Pig retainer control tops 24
4 Transport and storage 25
4.1 Storage conditions 25
4.2 Transport 25
4.2.1 Scope of supply 25
5 Technical data 26
5.1 Type plate 26
5.2 Technical data 26
5.3 Resistance of Sealing Materials 28
5.4 Pipe Ends 29
5.5 Tools 30
5.6 Lubricants 30
5.7 Weights 31
6 Assembly and installation 32
6.1 Safety instructions 32
6.2 Notes on installation 32
6.3 Valve with Detachable Pipe Connection Elements 32
6.4 Pneumatic connections 33
6.4.1 Air requirement for opening and closing the pig actuator (V3) 33
6.4.2 Air requirement for opening the pig retainer 33
6.4.3 Establishing Hose Connections 33
6.5 Electrical connections 34
6.5.1 General 35
6.5.2 Adjusting the initiators on the pig actuator 35
6.5.3 Initiator cabling 36
6.5.4 Position of proximity switch holder 36
6.5.5 Assignment of initiators 37
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6.5.6 Securing the magnetic switch on the pig station housing 37
7 Start-up 38
7.1 Safety notes 38
7.2 Notes on commissioning 38
7.3 Work steps 38
7.4 Avoiding damage 39
7.5 Removing the damage 39
8 Operation and control 40
8.1 Safety notes 40
9 Cleaning 41
9.1 Cleaning 41
9.1.1 Cleaning Process Examples 41
9.1.2 Cleaning effect 42
9.2 Passivation 42
10 Maintenance 43
10.1 Safety instructions 43
10.2 Inspections 44
10.2.1 Product contact seals 44
10.2.2 Pig 44
10.2.3 Pneumatic connections 44
10.2.4 Electrical connections 45
10.3 Maintenance intervals 45
10.4 Removing and inserting the pig 45
10.4.1 Preparations 45
10.4.2 Removing the pig 46
10.4.3 Inserting the pig 47
10.5 Dismantling the pig cleaning station 47
10.6 Disassembling the Valve 47
10.6.1 Removing the actuator 47
10.6.2 Removing fitted components 48
10.7 Disassembling the pig holder 49
10.8 Maintenance 50
10.8.1 Cleaning the pig cleaning station 50
10.8.2 Lubricating Seals and Threads 51
10.9 Installation 52
10.9.1 Assembling the pig actuator 52
Aligning the throttle check valve 52
Inserting the pig clamp 52
Assembling the cylinder pipe for pig cleaning station 4" OD 53
Adjusting the initiators on the pig actuator 53
Torques for the clamps and hinged clamps 53
Checking the function of the pig actuator 54
10.9.2 Assembling the pig retainer 55
Screw torques 55
Checking the function of the pig retainer 55
11 Alarms 56
11.1 Malfunctions and remedies 56
12 Decommissioning 57
12.1 Safety instructions 57
12.2 Disposal 57
12.2.1 General notes 57
12.2.2 Disposing of the pig retainer actuator and the spring package of the pig actuator 57
13 Spare parts list - pig cleaning station MST 3A 58
14 Parts list- Pig Cleaning Station MST 3A- DN 25 and 1"OD 63
15 Parts list – Feedback for MST-DK pig actuator 66
16 Parts list – Pigs DN and OD 68
17 Parts list – Pig Retainer 3A with T.VIS M-15 and A-15 70
18 Parts list – Pig Retainer MSP 3A with T.VIS M-15 and A-15 73
19 Parts list – Connection 0 and Proximity Switch Holder for Pig Retainer 76
20 Parts list – Connection 0 / Proximity Switch Holder for Pig Retainer MSP 79
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21 Dimension sheet: Pig Cleaning Station MST 3A/DN40-DN100/1.5"OD-4"OD 82
22 Dimension sheet: Pig Cleaning Station MST 3A – sizes DN25 and 1"OD 84
23 Dimension sheet – free cross-sectional area on pig station housing 86
24 Appendix 88
24.1 Lists 88
24.1.1 Abbreviations and terms 88
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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
Pig cleaning station MST 3A is installed directly on the product line and is used
for the intake of a pig.
When flowing product or cleaning agent through the station, the pig remains fixed
in position and the liquid flows around it. You can choose the direction of flow
through the station. The pig cleaning position can be circulated with liquid, with or
without the pig in place.
During cleaning, the pig surface is also completely cleaned.
Hint!
The manufacturer is not liable for damage caused by improper use of
the pig cleaning station. 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 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.
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,
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.
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.
When working with the component, a distinction is made between the following
user groups:
Safety
Supplementary Regulations
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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
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.
Signs on the valve
Sign Meaning
Fig.1
General hazard warning
Fig.2
Warning Crushing
Safety
Safety equipment
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Signs on the valve
Sign Meaning
Fig.3
Explosive atmosphere hazard warning
Fig.4
Ventilate the product line and actuator
prior to disassembly!
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 Danger zones
Please observe the following notes:
Safety
Danger zones
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Fig.5
Before undoing the hinged clamps (53) for pig removal, it must be ensured that
•no program is running, such as production, pigging or cleaning,
•no program can be started, such as production, pigging or cleaning,
•the pipe and pig cleaning station are empty,
•the pipe and pig cleaning station are free of overpressure by means of
opened vent valves, and
•all air hoses are pulled out of the connections (V3.1, V3.2) on the pig actuator.
Please observe the following notes:
•In the event of malfunctions, shut down the pig cleaning station (disconnect
from the power and air supply) and secure it against being used.
•Never reach into the lantern of the pig retainer (9) or into the pig actuator
(V3). Fingers can be crushed or cut off.
•Before starting any service, maintenance or repair work, disconnect the pig
cleaning station 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.
Safety
Danger zones
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•Regularly check the electrical equipment of the pig cleaning station.
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. Wear suitable protective gloves
when transporting and installing the pig cleaning station.
•The rods in the pig station housing can break if the initiators are incorrectly
adjusted or if there are errors in the program.
Safety
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3 Description
3.1 Design
Fig.6
Design
No. Designation
A Pig
C Pig retainer (air-opening/spring-closing)
Q Control top
3 Lantern
7 Pig station housing
V3 Pig actuator
Description
Design
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3.2 Functional description
3.2.1 Pig cleaning station
3.2.1.1 Production
All actuators on the pig cleaning station are in rest position. The pig is held in
place in its position in the pig housing where cleaning agent can flow around it.
The pig position is continually monitored by a magnetic switch E1.1. Product can
flow through the pig cleaning station from A to B and vice-versa.
Fig.7
3.2.1.2 Sending the pig
Fig.8: Pig in sending position
Prerequisite:
•Production is complete
•The pig position is detected by means of a magnetic switch E1.1.
Description
Functional description
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