GEA VARIVENT K Bedienungsanleitung

Hygienic valves

GEA VARIVENT® valve type K

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 Staff 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 Actuator Function 20

4 Transport and storage 21

4.1 Storage conditions 21

4.2 Transport 21

4.2.1 Scope of supply 22

5 Technical data 23

5.1 Type plate 23

5.2 Technical data 23

5.3 Resistance and permitted operating temperature of the sealing materials 24

5.4 Pipe ends - General table of measurements 26

5.5 Dimensions leakage pipe 27

5.6 Tool 27

5.7 Lubricants 28

5.8 Weights 28

6 Assembly and installation 29

6.1 Safety instructions 29

6.2 Notes on installation 29

6.3 Control head 29

6.4 Valve with Detachable Pipe Connection Elements 29

6.5 Valve with Welded Ends 30

6.6 Pneumatic connections 31

6.6.1 Air Requirement 31

6.6.2 Establishing Hose Connections 31

6.7 Electrical connection with T.VIS control top 32

7 Start-up 33

7.1 Safety instructions 33

7.2 Notes on commissioning 33

8 Operation and control 34

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8.1 Safety instructions 34

9 Cleaning 35

9.1 Cleaning 35

9.1.1 Cleaning Process Examples 35

9.1.2 Cleaning effect 35

9.1.3 Cleaning the Leakage Cavity 36

9.2 Passivation 36

10 Maintenance 37

10.1 Safety instructions 37

10.2 Inspections 38

10.2.1 Product contact seals 38

10.2.2 Pneumatic connections 38

10.2.3 Electrical connections 38

10.3 Maintenance intervals 39

10.4 Prior to disassembly 39

10.5 Disassembling the Valve 39

10.5.1 Removing the Valve Insert 40

10.5.2 Separating the Valve from the Actuator 41

10.6 Maintenance 43

10.6.1 Cleaning the Valve 43

10.6.2 Replacing Seals 44

Note on Seal Replacement 44

Replacing the V-Ring 44

10.6.3 Lubricating seals and threads 45

10.7 Installation 46

10.7.1 O-ring 46

10.7.2 Guide rings 47

10.7.3 Spring 47

10.7.4 Leakage pipe 47

10.7.5 Torques for the Clamps and Clamp Connections 47

10.7.6 Strokes depending on size 48

11 Alarms 50

11.1 Malfunctions and remedies 50

12 Decommissioning 51

12.1 Safety instructions 51

12.2 Disposal 51

12.2.1 General notes 51

12.2.2 Valve Actuator Disposal 51

13 Spare parts list - mixproof valve K 52

14 Dimension Sheet - VARIVENT® Double Seat Valve K 64

15 Appendix 66

15.1 Lists 66

15.1.1 Abbreviations and terms 66

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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 double seat valve K is used for the mixproof separation of cleaning media at

flow path intersections in pipe systems without the possibility of leakage chamber

cleaning. It can be used as cleaning and gas valve in CIP systems and gas

fittings.

The medium should preferably flow in the opening direction of the valve disc 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 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 component is a piece of pressure equipment (without safety function) in the

sense of the pressure equipment directive 2014/68/EU. Classified according to

Annex II in category 1.

According to the scope of directive 2014/34/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 DN 25 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.

Safety

Intended use

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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.

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.

Safety

Operator’s Duty of Care

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