GEA VARIVENT Bedienungsanleitung

Hygienic valves

GEA VARIVENT® control valve type P

Operating instruction (Translation from the original language)

430BAL011665EN_5

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

2 Safety 8

2.1 Intended use 8

2.1.1 Requirements for operation 8

2.1.2 Pressure equipment directive 8

2.1.3 ATEX directive 8

2.1.4 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 13

2.7.1 Signage 13

2.8 Residual dangers 13

2.9 Danger zones 14

3 Description 17

3.1 Design 17

3.2 Functional description 19

3.2.1 Control valve type P- P_F / P_J 19

3.2.2 Control valve type P - divert valve W/X 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 24

5.3 Seat leakage according to DIN EN 60534-4 25

5.4 Resistance and permitted operating temperature of the sealing materials 26

5.5 Pipe ends - General table of measurements 27

5.6 Tools 29

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

7.2 Notes on commissioning 34

8 Operation and control 35

8.1 Safety instructions 35

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9 Cleaning 36

9.1 Cleaning 36

9.1.1 Cleaning Process Examples 36

9.1.2 Cleaning effect 36

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

10.3 Maintenance intervals 40

10.4 Prior to disassembly 40

10.5 Disassembly 40

10.5.1 Disassembling Control Valve Type P-P_F / P_J / Disassembling Control Valve Type P - 3-Stage Seat K 41

10.5.2 Control Valve Type P - Disassembling Divert Valve W 47

10.5.3 Control Valve Type P - Disassembling Divert Valve X 53

10.6 Maintenance 59

10.6.1 Cleaning the Valve 59

10.6.2 Replacing Seals 60

10.6.3 Lubricating Seals and Threads 61

10.7 Installation 62

10.7.1 Installing the valve 62

10.7.2 Torques for the Clamps and Clamp Connections 63

10.7.3 Checking the function 64

11 Alarms 66

11.1 Malfunctions and remedies 66

12 Decommissioning 67

12.1 Safety instructions 67

12.2 Disposal 67

12.2.1 General notes 67

12.2.2 Valve Actuator Disposal 67

13 Spare parts list - VARIVENT control valve type P P_F/P_J 68

14 Spare parts list - VARIVENT control valve type P, divert valve W/X 102

15 Spare parts list - VARIVENT control valve type P 3-stage seat K 107

16 Dimensions sheet - VARIVENT control valve type P P_F/P_J 112

17 Dimensions sheet - VARIVENT control valve type P, divert valve W/X 114

18 Dimensions sheet - VARIVENT control valve type P 3-stage seat K 116

19 Appendix 118

19.1 Lists 118

19.1.1 Abbreviations and terms 118

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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

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 Büchen, Germany

Büchen, 24 January 2020

Franz Bürmann

Managing Director i.V. Matthias Südel

Head of Engineering

General Information

EU Declaration of Conformity in accordance with the EC Machinery Directive 2006/42/EC

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2 Safety

2.1 Intended use

The control valve is used to control flow rates and pressures in automated

process plants.

The medium should preferably flow in the opening direction of the valve disk to

avoid pipe hammers when the valve is opened or closed.

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 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: 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

If the control valves are used in areas with a potentially explosive atmosphere,

you must absolutely comply with directive 2014/34/EU with respect to all ignition

hazards.

The supplementary ATEX operating instructions for VARIVENT valves must be

observed. For details regarding the marking of valves for potentially explosive

areas also refer to the additional ATEX operating instructions for VARIVENT

valves.

If used in explosion-proof areas, the regulations laid down in the European

standards DIN EN 60079-0 and DIN EN 60079-11 must be observed.

2.1.4 Improper operating conditions

Safety

Intended use

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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.

•Observe the Technical Data specified and the limits of use!

Safety

Operator’s Duty of Care

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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

•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.

Safety

Subsequent changes

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