GEA T-smart 7 Bedienungsanleitung

Hygienic valves

GEA T-smart 7 butterfly valve

Operating instruction (Translation from the original language)

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These Operating Instructions are the English translation of the original operating

instructions in the sense of the EU Machinery Directive. This document is

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

2 Safety 8

2.1 Intended use 8

2.1.1 Requirements for operation 8

2.1.2 Flow speed 8

2.1.3 Pressure equipment directive 8

2.1.4 ATEX directive 8

2.1.5 Improper operating conditions 8

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

2.4.2 Environmental Protection 10

2.4.3 Electrical Equipment 11

2.5 Supplementary Regulations 11

2.6 Qualification of personnel 11

2.7 Safety equipment 12

2.7.1 Signage 12

2.8 Residual dangers 13

2.9 Hazard Areas 14

3 Description 16

3.1 Butterfly valve with control top 16

3.2 Butterfly valve without control top 16

3.3 Intermediate flange design – VV (788) 17

3.4 Manual actuator 17

3.5 Functional description 19

3.5.1 Pneumatic Actuator 19

3.5.2 Actuator A.1 19

3.5.3 Actuator A.2 19

3.5.4 Manual Actuator Type H 20

3.5.5 Butterfly Valve Body without Actuator 20

4 Transport and storage 21

4.1 Storage conditions 21

4.2 Transport 21

4.2.1 Scope of supply 21

5 Technical data 22

5.1 Type plate 22

5.2 Technical data 22

5.3 Resistance of Sealing Materials 24

5.4 Pipe ends - General table of measurements 25

5.5 Tool 26

5.6 Lubricants 27

5.7 Weights 27

6 Assembly and installation 29

6.1 Safety instructions 29

6.2 Notes on installation 29

6.3 Butterfly Valve with Welding Flange Design 29

6.4 Butterfly Valve with Intermediate Flange Design 30

6.5 Butterfly valve with screw connection (G, K, C) 31

6.6 Pneumatic connections 31

6.6.1 Air Requirement 32

6.6.2 Establishing Hose Connections 32

6.6.3 Actuator with T.VIS Control Top 32

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6.6.4 Actuator without Control Top 32

6.7 Electrical connections 32

6.7.1 Electrical connection with T.VIS control top 33

6.7.2 Adjusting the proximity switch – actuator without T.VIS 33

7 Start-up 35

7.1 Safety instructions 35

7.2 Notes on commissioning 35

8 Operation and control 36

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 Rinsing operations 38

9.2 Passivation 38

10 Maintenance 39

10.1 Safety instructions 39

10.2 Inspections 40

10.2.1 Pneumatic connections 40

10.2.2 Electrical connections 40

10.2.3 Mechanical Connections 40

10.3 Maintenance intervals 41

10.4 Prior to disassembly 41

10.5 Disassembling the Valve 41

10.5.1 Removing the T.VIS M-15 Control Top 42

10.5.2 Removing control top type T.VIS P-15 and A-15 43

10.5.3 Removing the proximity switch – actuator without T.VIS 44

10.5.4 Intermediate flange design type VV – removing the valve 44

10.5.5 Disconnecting the actuator 44

10.5.6 Dismantling the Actuator Parts 45

10.5.7 Removing the manual actuator H 46

10.5.8 Removing the Valve Disk Seal 46

10.6 Maintenance 49

10.6.1 Cleaning the Valve 49

10.6.2 Lubricating Seals and Threads 50

10.7 Installation 51

10.7.1 Assembling the Valve Disk 51

10.7.2 Torques for the Clamps and Clamp Connections 52

11 Alarms 53

11.1 Malfunctions and remedies 53

12 Decommissioning 54

12.1 Safety instructions 54

12.2 Disposal 54

12.2.1 General notes 54

12.2.2 Valve Actuator Disposal 54

13 Parts list - Manual actuator for butterfly valve T-smart 7 55

14 Spare parts list - Pneumatic actuator 57

15 Parts list - Butterfly valve body T-smart 7 61

16 Parts list - Butterfly valve 788 77

17 Dimension sheet - T-smart 7 83

18 Dimension sheet - Butterfly valve T-smart 7 VV 88

19 Dimension sheet - Butterfly valve T-smart 7 - flanges 91

20 Appendix 94

20.1 Lists 94

20.1.1 Abbreviations and terms 94

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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.:+49 4155 49-0

Fax:+49 4155 49-2035

[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: T-smart

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 butterfly valve is used to open and partially or fully shut off pipe sections.

Using the device for any other purpose is considered contrary to its designated

use.

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 Flow speed

With slow flow speeds, existing solids holding space can potentially settle.

When the butterfly valve is closed quickly, this causes negative pressure on the

disk and in the area of the butterfly valve seal, as a result of a stall. With flow

speeds of ≥ 3.5 m/s, the valve may only be closed with significantly reduced

speed.

2.1.3 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.

2.1.4 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.

2.1.5 Improper operating conditions

The operational safety of the component can not be guaranteed under improper

operating conditions. Therefore avoid improper operating conditions.

Safety

Intended use

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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.

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.

Safety

Operator’s Duty of Care

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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

•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.

Safety

Subsequent changes

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