GEA VARIVENT DN 25 Bedienungsanleitung

Hygienic valves

GEA VARIVENT® Double-Seat Valve Type R

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.

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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

2.1.3 ATEX directive 9

2.1.4 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 11

2.4.2 Environmental Protection 12

2.4.3 Electrical Equipment 12

2.5 Supplementary Regulations 12

2.6 Qualification of personnel 12

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 20

3.2.1 Leakage-Proof Shut-Off 20

3.2.2 Cleaning function 20

3.2.3 Actuator Function 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 and permitted operating temperature of the sealing materials 26

5.5 Pipe ends - General table of measurements 27

5.6 Tool 28

5.7 Lubricants 29

5.8 Weights 29

6 Assembly and installation 30

6.1 Safety instructions 30

6.2 Notes on installation 30

6.3 Control head 30

6.4 Valve with Detachable Pipe Connection Elements 30

6.5 Valve with welded ends 31

6.6 Pneumatic connections 32

6.6.1 Air Requirement 32

6.6.2 Establishing Hose Connections 32

6.7 Electrical connection with T.VIS control top 33

7 Start-up 34

7.1 Safety instructions 34

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7.2 Notes on commissioning 34

8 Operation and control 35

8.1 Safety instructions 35

9 Cleaning 36

9.1 Cleaning 36

9.1.1 Cleaning Process Examples 36

9.1.2 Cleaning effect 36

9.1.3 Cleaning the Leakage Cavity 37

9.2 Passivation 37

10 Maintenance 38

10.1 Safety instructions 38

10.2 Inspections 39

10.2.1 Product contact seals 39

10.2.2 Pneumatic connections 39

10.2.3 Electrical connections 39

10.2.4 Signs on the valve 40

10.3 Maintenance intervals 40

10.4 Prior to disassembly 40

10.5 Disassembly 41

10.5.1 Start disassembly 41

10.5.2 Removing the control top 42

10.5.3 Disconnecting the Valve from the Housing 44

10.5.4 Disassembling the Valve into Individual Parts 44

10.5.5 Disassembly balancer plug 45

10.5.6 Disassembly of the housing combination 46

10.6 Installation 46

10.6.1 Torques for the clamps and clamp connections 46

10.6.2 Assembling the valve from individual parts 46

10.6.3 Fitting the control top 48

10.6.4 Assembly of the housing combination 49

10.6.5 Assembly balancer plug 50

10.6.6 Installing the valve insert in the housing 52

10.6.7 Checking the function 53

10.7 Maintenance 54

10.7.1 Cleaning the valve 54

10.7.2 Replacing Seals 55

Replacing V-Ring double-disk 55

Replacing V-Ring RA valve disk 57

Replace more seals 58

10.7.3 Lubricating seals and threads 59

11 Alarms 61

11.1 Malfunctions and remedies 61

12 Decommissioning 62

12.1 Safety instructions 62

12.2 Disposal 62

12.2.1 General notes 62

12.2.2 Valve Actuator Disposal 62

13 Spare parts list - Double seat valve R 63

14 Dimension sheet - VARIVENT® double seat valve R 75

15 Appendix 77

15.1 Lists 77

15.1.1 Abbreviations and terms 77

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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 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 mixproof valve R is used for the mix-proof shut-off of high-grade, non-

abrasive products at intersection points in pipe systems.

It is resistant to pressure surges in its closed state.

Hint!

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 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 valve is a piece of pressure equipment (without safety function) in the sense

of the pressure equipment directive 2014/68/EU: They are classified according to

Annex II in category 1.

According to the scope of directive 2014/64/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 DN25 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.

2.1.3 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”.

Safety

Intended use

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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 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.

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.

Safety

Operator’s Duty of Care

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