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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