GEA VARIVENT Series Bedienungsanleitung

Hygienic valves

GEA VARIVENT Sampling Valve Type I

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

1.5 EC - Declaration of conformity in accordance with the Pressure Equipment Directive 2014/68/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 Improper operating conditions 9

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 11

2.4.2 Environmental Protection 11

2.4.3 Electrical Equipment 11

2.5 Supplementary Regulations 12

2.6 Qualification of personnel 12

2.7 Safety equipment 13

2.7.1 Signs 13

3 Description 15

3.1 Design of the valve 15

4 Transport and storage 16

4.1 Scope of supply 16

4.2 Transport 16

4.3 Storage conditions 16

5 Technical data 17

5.1 Type plate 17

5.2 Technical data 17

5.3 Resistance of the sealing materials 18

5.4 Pipe ends - General table of measurements 19

5.5 Lubricants 20

6 Assembly and installation 21

6.1 Safety instructions 21

6.2 Notes on installation 21

6.3 Valve with Detachable Pipe Connection Elements 21

6.4 Valve with Welded Ends 22

7 Start-up 23

7.1 Safety instructions 23

7.2 Notes on commissioning 23

8 Operation and control 24

8.1 Safety instructions 24

9 Cleaning and Passivation 25

9.1 Cleaning 25

9.1.1 Cleaning Process Examples 25

9.1.2 Cleaning effect 25

9.2 Passivation 26

10 Maintenance 27

10.1 Safety instructions 27

10.2 Inspections 28

10.3 Maintenance intervals 28

10.4 Prior to removal 29

10.5 Disassembling the Valve 29

10.5.1 Removing the valve disk 30

10.5.2 Removing the handwheel 30

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10.6 Maintenance 31

10.7 Installing the valve 32

11 Alarms 33

11.1 Malfunctions and remedies 33

12 Decommissioning 34

12.1 Safety precautions 34

12.2 Disposal 34

12.2.1 General notes 34

13 Parts list - sampling valve I 35

14 Appendix 45

14.1 Lists 45

14.2 Abbreviations and terms 45

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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: 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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1.5 EC - Declaration of conformity in accordance with the Pressure Equipment

Directive 2014/68/EU

Manufacturer:

GEA Tuchenhagen GmbH

Am Industriepark 2-10

21514 Büchen

We hereby declare that the product series designated below, based on their design, type and version brought

to market by us, complies with the basic health and safety requirements of the Pressure Equipment Directive.

This declaration will become invalid if any alterations are made to the pressure equipment which have not

been agreed with us.

Product series: VARIVENT®, ECOVENT®, VARINLINE®

Serial numbers: 140000 - 169999

Relevant EC directives: 2014/68/EU Pressure Equipment Directive

Category I

Conformity assessment

procedure

(Internal production control)

Applicable harmonized standards,

in particular:

DIN EN 13445-3:2014-12 Experimental methods (burst test)

Other applied standards and

technical specifications:

DIN EN 10088-1

DIN EN 10088-2

DIN EN 10088-3

DIN EN 12516

Materials standard

Industrial valves - Shell design

strength

Remarks: –Valid for substances of fluid group 2.

If substances of fluid group 1 are used, a new

assessment must be carried out.

–The nominal diameters DN25, 1”OD and smaller

are subject to article 4, paragraph 3 of the

Pressure Equipment Directive which specifies

sound engineering practice.

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, 08/11/2017

Matthias Südel

Senior Director

Product Development Flow Components

Michael Wulle

Managing Director

General Information

EC - Declaration of conformity in accordance with the Pressure Equipment Directive 2014/68/EU

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2 Safety

2.1 Intended use

The sampling valve type I is intended for drawing samples of liquids and viscous

media.

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: 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.

•Clamp connections or screw fastenings on the housing are not properly

fastened and secured against accidental loosening.

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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