GEA VARIVENT TSVN Bedienungsanleitung

Hygienic valves

GEA VARIVENT® Sampling valve type TSVN and TSVN

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

2.2 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

Safety instructions 11

2.4.2 Environmental Protection 11

2.4.3 Electrical Equipment 12

2.5 Supplementary Regulations 12

2.6 Qualification of personnel 12

2.7 Safety equipment 13

2.7.1 Signs 13

3 Transport and storage 15

3.1 Scope of supply 15

3.2 Transport 15

3.3 Storage conditions 15

4 Technical data 16

4.1 Type plate 16

4.2 Technical data 16

4.3 Resistance and permitted operating temperature of the sealing materials 17

4.4 Pipe ends (R) 19

4.5 Lubricants 19

5 Description 20

5.1 Design of the valve 20

6 Assembly and installation 22

6.1 Safety instructions 22

6.2 Notes on installation 22

6.3 Valve with Detachable Pipe Connection Elements 22

6.4 Welding In a Valve with Pipe Connection 23

6.4.1 Valve with Welded Ends 23

7 Start-up 25

7.1 Safety instructions 25

7.2 Commissioning activities 25

8 Cleaning and Passivation 26

8.1 Cleaning 26

8.1.1 Cleaning Process Examples 26

8.1.2 Cleaning effect 26

8.2 Passivation 27

9 Maintenance 28

9.1 Safety instructions 28

9.2 Inspections 29

9.3 Maintenance intervals 29

9.4 Prior to removal 30

9.5 Disassembling the Valve 30

9.5.1 Removing the valve 31

9.5.2 Removing the valve disk 31

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Valve TSVU without bellows 32

Valve TSVU with bellows 33

9.5.3 Removing the handwheel 33

Valve TSVN 33

Valve TSVU 34

9.6 Maintenance 35

9.6.1 Cleaning the valve 35

9.6.2 Replacing seals 35

9.6.3 Lubricating seals and threads 35

9.7 Installation 37

9.7.1 O-Ring on the valve disk 37

9.7.2 Fitting the piston 37

9.7.3 Fitting position 37

10 Alarms 38

10.1 Malfunctions and remedies 38

11 Decommissioning 39

11.1 Safety precautions 39

11.2 Disposal 39

11.2.1 General notes 39

12 Appendix 40

12.1 Lists 40

12.2 Abbreviations and terms 40

13 Spare parts list - Sampling valve TSVN" 42

14 Dimension sheet - VARINLINE® Sampling valve, type TSVN 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 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 sampling valve TSVN/TSVU is intended for taking 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 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.

2.2 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.

Safety

Intended use

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•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

You should never make any technical modifications to the valve. 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 Aseptomag AG should be

fitted. This ensures the reliable and economical operation of the valve.

2.4 General safety instructions and dangers

The valve is operationally reliable. It was built according to state-of-the-art

science and technology.

Nevertheless, the valve can pose dangers, especially if

•the valve is not used in accordance with its intended use,

•the valve is not used correctly,

•the valve is operated under impermissible operating 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.

Safety

Subsequent changes

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